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Small, cheap & easy do it yourself air cleaner (lots of pics)

Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
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Old 03-17-2015, 06:22 PM
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Small, cheap & easy do it yourself air cleaner (lots of pics)

  #1  
Old 02-01-2011, 12:28 AM
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Default Small, cheap & easy do it yourself air cleaner (lots of pics)

I've done a ton of these air cleaners. They work with both carbed and EFI Sportsters. Super cheap & easy so I thought I'd share.

4" air cleaner assembly from Auto Zone. 12 or 13 bucks.

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Cheapy carb mount from Jireh, Ebay, J&P (or whoever is your fav)

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This is what you'll find in the kit from Auto Zone.

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The flange on the backside has to go.

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Cut it off with a cut off wheel, hack saw or whatever. It's aluminum so it cuts easy.

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Position it on the carb mount bracket.

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You can see that the hole in the air cleaner backing plate is a bit too big to drill holes for mounting so I use a file to knock out notches.

Again, this part is aluminum so it's pretty easy to do. Just be patient and keep test fitting it...you don't want to notch it too much. Get comfy & file away.

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It'll attach with the carb mount bracket bolts & the washers secure it tight.

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The filter sits flush in the backing plate so the bolts will be in the way.

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Give the filter the same notching treatment.

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Fitted

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Install the stud that comes in the kit and run a nut down the threads to keep the filter cover from squishing when you attach it.

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It's a crap shoot that the air cleaner kit comes with the hardware so pick up a 1/4-20 hex nut

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Or an acorn nut

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But I use a wing nut

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Continued below...
 
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Old 02-01-2011, 12:28 AM
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I left the cover chrome on this one but you can change it up. I rubbed it out with a Scotchbrite pad on the one on the left.

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Or paint/powder whatever color you want. This one is powdercoated satin black.

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The paper filter looks old school and works just fine. Replacement filters are also available at Auto Zone. But for you guys that wear designer jeans, a 4" K&N fits perfectly. Part # E-3120.

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The K&N is also available at Auto Zone but is usually cheaper from Jegs or Summit Racing. Even if you choose to spring for the K&N the whole deal is still super cheap compared to other 4" filter kits.

Thanks for looking...
 
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Old 02-01-2011, 01:16 AM
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Looks pretty good! Nice work!
 
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Old 02-01-2011, 01:36 AM
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Sweet I think I'm going to give this a go. I'm in the uk so rains a pain what would you use to sock it?
 
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Old 02-01-2011, 01:40 AM
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K&N makes a filter cover.
 
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Old 02-01-2011, 01:45 AM
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I don't sock it. Water isn't going to hurt unless it's submerged. Back in the day I used to watch my dad pour water in his carbs while the motor was running to clean em out.

But if you must have a cover buy this instead of the unit from Auto Zone. You might have to trim a bit off of the cover to clear the carb top but that's an easy fix.

http://www.speedwaymotors.com/Louver...ners,7201.html
 
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Old 02-01-2011, 04:08 AM
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Excellent tutorial,and as always great work.H.
 
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Old 02-01-2011, 05:23 AM
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nice job. just shows what a little ingenuity can accomplish.
 
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Old 02-01-2011, 05:30 AM
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Great job! Funny what a little creative ingenuity & McGyver instinct will produce. I'd say it's a nice change from the std HD look...thanks for posting.
 
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Old 02-01-2011, 05:40 AM
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Thanks!
 

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