again inspired by miguel's dragon and the latest air box changes he has done
where he has installed smaller round air filters in his rebel ...
plus being tired of the $30-40 stock filter cost at the dealer
and where the stock design actually contributes to ruining itself with the crank fumes
... I decided to search around and rig something up ...

(Tecumseh # 30727, Cub Cadet # 488619, John Deere # AM30900)



MATERIALS :

- Tecumseh lawnmower round air filter (ID 2 3/8" OD 3 3/4" Height 2") - from menard's @ $2.36
- Fernco Plumb Quick rubber pipe connector 1 1/2 to 1 1/4" - from menard's @ $1.04
- Watts nylon tubing hose barb to MIP elbow 1/4" to 1/4" - from menard's @ $0.59

TOOLS :

- Straight back razor blade (or exacto knife or carpet cutter)
- Yankee ingenuity (Rebel pun intended)


see the diagram below for cutting the rubber plumbing connector
tho when i made a second one i decided to only cut off the larger end channel
and to leave the lip on the small end to help secure it in the carb better
this means it is slightly too large to fit into the carb gasket
so will need to be pinch inserted and moved around a little to seat it







One of the posters on the honda rebel forum created a video of the air filter access procedure :

Scotchy's Rebel Air Box access Video



and the reduced size of the new filter even came in handy later when i was working on the latest
lighting upgrade(round 3) and needed a place to stash the circuit breaker tap and the switch relays



CLICK HERE to see my AIR BOX MODIFICATION PROJECT for the exterior decor work









Latest Developments


took the rebel to the shop for its spring cleaning/tune up before taking it to texas

the shop has a new dyno and i had them put it on and tune the carbs while it was there
interesting development ... stay tuned for more details when i get the time to post a proper write up etc ...






MATERIALS :

- Spectre 4" round air filter (part # 4790) - from pep boy's @ $14.99
(note: replacement filter units = Spectre part # 4809 @ $5.99)
- Fernco Plumb Quick rubber pipe connector 1 1/2 to 1 1/4" - from menard's @ $1.04
- Watts nylon tubing hose barb to MIP elbow 1/4" to 1/4" - from menard's @ $0.59

TOOLS :

- Straight back razor blade (or exacto knife or carpet cutter)
- Yankee ingenuity (Rebel pun intended)


see the diagram below for cutting the rubber plumbing connector
this newest adaption is even simpler - no cutting of the recessed areas
the only cutting is now just the side hole for the threaded hose nipple unit
again, the lip on the small end is slightly larger than the airbox carb opening
this means it will need to be pinch inserted and moved around a little to seat it



the stock air filter has a self detructive habit of fouling itself because of the location of the breather return tube - and its sorta expensive at 35-40$ ... the lawn mower filter i used for the first mod is much cheaper and the rubber mounting plumbing part i used as an adaptor let me relocate the return tube 'down wind' of the filter paper and solved the oily fouling issue

HOWEVER

i had it in at the shop and they put it on the dyno and found out that the lawn mower filter is slightly restrictive - the result being that it gets a little too rich at higher revs when the throttle is opened all the way - so they said to put it back on the factory filter - which i did - and they tuned the carb ... result was a teeny mid-range boost in peppiness but a lost of 5mph top end (running rich from the lawn mower filter wasn't all bad)

not happy about being back on the stock foul up filter, i went hunting ... again

in pep boys i found an automotive high flow air filter by spectre 4" round and 2" tall and the kicker is it fit the adaptor plumbing part i used for the lawn mower one

installed it this past week .....
LOTS more zip in the bike now - top end seems pretty much the same tho
..... still testing - and will put it back on the dyno this summer
when the shop has a open house special sale on dyno runs