Renegade CVT Intake Snorkel

[stray]

one of the main complaints from renegade/outlander owners is the location of the engine air intake and cvt intake. they are inside the left front fender well and tend to get a fair amount of water/mud in them, regardless of how deep you are riding. i will be stealth snorkeling the cvt intake and exhaust, and blocking off the engine air intake and cutting a 2" or larger hole in the airbox lid, using frogskins or flow-rite intake screens. today, i did the cvt intake, using 2" abs plastic, available at most home improvement stores. i must stress this is a process of test fitting each piece, while making sure all of the previous pieces are still where you want them to be. do not glue anything until you are certain everything fits, where you want it. then mark the pieces, take it apart and make it permanent.

first step is to remove the seat and front plastics. then remove the outer cover of the box that contains the stock air inlets. it's inside the left front fender well and is held in by three pushpins. here's a picture showing why this mod is necessary. keep in mind, the deepest i've had this bike is around one foot (so far).

http://i304.photobucket.com/albums/n...4/IM001626.jpg


the engine intake is at the top, kinda rectangular. cvt intake at the bottom, almost round.


next, you must remove the back half of the box that surrounds the inlets. a couple more pushpins and an 8mm bolt are holding it in. i also removed the 10mm bolt securing the engine air intake to the frame to make it easier. this thing needs to be flexed a little to get it out, just be careful. it also helps to remove the cvt air inlet from the cvt housing (another 8mm bolt), loosen the hose clamp closest to the front of the bike.

http://i304.photobucket.com/albums/n...4/IM001629.jpg


here's what the inlet looks like, removed.

http://i304.photobucket.com/albums/n...4/IM001634.jpg

here's where i decided to trim mine.

http://i304.photobucket.com/albums/n...4/IM001635.jpg

and what it looked like, trimmed.

http://i304.photobucket.com/albums/n...4/IM001637.jpg

you'll need to attach a 2" rubber 90 degree elbow to the end that has been shortened, with the other end of the rubber 90 coming up into the pod area.

http://i304.photobucket.com/albums/n...4/IM001643.jpg

next is a 2" street 90 degree fitting that is facing the rear of the bike, angled slightly towards the center. in this picture, it's pointing towards the other side of the bike. you can see the line where i will be cutting away a little plastic to make some room. note that i am leaving approximately 3/8" before the angle, to retain strength.

http://i304.photobucket.com/albums/n...4/IM001640.jpg

now add a short section of 2" abs pipe (approx. 3") and a hard 90 degree fitting. notice the plastic has been cut away.

http://i304.photobucket.com/albums/n...4/IM001644.jpg

initially, i had the final fitting turned towards the outside. it fit, but i felt the airflow may be a little restricted once the plastic was put back on, so i turned it to face inside. note the intimidating shifter knob.

http://i304.photobucket.com/albums/n...4/IM001646.jpg

http://i304.photobucket.com/albums/n...4/IM001648.jpg

http://i304.photobucket.com/albums/n...4/IM001649.jpg

http://i304.photobucket.com/albums/n...4/IM001650.jpg

here is the entire snorkel.

http://i304.photobucket.com/albums/n...4/IM001651.jpg

http://i304.photobucket.com/albums/n...4/IM001652.jpg

when attaching the rubber 90 to the modified stock air inlet, the hose clamp wanted to compress the plastic and slide off. i used three 1/8" rivets with 1/4" clinch.

http://i304.photobucket.com/albums/n...4/IM001655.jpg

all of the plastic to rubber connections had hose clamps and were sealed with silicone on the inside, including the rivet holes. the abs to abs connections were glued with abs cement and allowed to dry.

when re-installing the inner half of the plastic box that originally contained the air inlets, you will need to remove a small section of the plastic.

http://i304.photobucket.com/albums/n...4/IM001670.jpg

http://i304.photobucket.com/albums/n...4/IM001671.jpg

http://i304.photobucket.com/albums/n...4/IM001672.jpg



tomorrow, the cvt exhaust snorkel...

[BATTLEGUN]

Man that is pretty simple in concept. Very nice write-up. How long have you had this done or was this literally last night? I'm curious about how it holds up to the abuse we divy our quads. There is no doubt in my mind it resist water better than the stock set up.

Again, very nicely detailed install notes and pictures (and I like the shifter )

Would you like me to embed those images or did you want to leave the images as links for readability?

[GRIZZLYWIZARD]

Embedded the images for you. Just click the link if you need to see a bigger image.

Great write up man.

[Mack450]

Mannn! Sweet set up! I tell ya every time I see a Renegade I start dreaming about having one.

[stray]

Originally Posted by BATTLEGUN

Man that is pretty simple in concept. Very nice write-up. How long have you had this done or was this literally last night? I'm curious about how it holds up to the abuse we divy our quads. There is no doubt in my mind it resist water better than the stock set up.

Again, very nicely detailed install notes and pictures (and I like the shifter )

Would you like me to embed those images or did you want to leave the images as links for readability?

thanks, it was done yesterday, but i will definitely post any issues or updates after putting it through some serious torture!

[stray]

Originally Posted by GRIZZLYWIZARD

Embedded the images for you. Just click the link if you need to see a bigger image.

Great write up man.

thanks, and thank you for taking care of the pics - it was late...

[stray]

Originally Posted by Mack450

Mannn! Sweet set up! I tell ya every time I see a Renegade I start dreaming about having one.

thanks! once i rode one, i knew i had to have my own!

[stray]

added a few pics of putting the cover back in.

[BATTLEGUN]

I meant to ask, what's the parts list for the hardware store? I can see what you used, but a list always makes it easier for over tasked people like me.

[stray]

i'll see what i can do...