This mod is for the 2006 Outlander 800's

Locate the black plastic 90 degree elbow that connects the Air filter to the throttle body (BTW: My air filter was very loose and slipped off with no effort. Make sure yours is tight enough from the factory). Remove the 90 degree elbow and take a look how it flows. It has some big fat injection molding burrs on the inside on both ends. On mine the burrs were sharp all the way around and reduced the opening size about 4mm on each end. These burrs also break up the laminar airflow and don't allow a smooth transition from the filter to the throttle body. I de-burred them with an exacta knife, a rounded file and then I sanded them flush. Try to keep it stock looking. Remember to stuff a rag in the throttle body and to do the work away from the bomb.

The other item was a big burr on the snorkel entering the air box. If you feel the snorkel entering the air box you "might" find a sharp edge that reduces the airflow 5-10%. Your bomb may not have this burr. I trimmed and sanded it then vacuumed out the dust.

I did some before and after runs on my G-Tech RR and I gained almost 1.5-2 hp and .03 G's in the mid to upper rpm's. Not bad for 45 minutes worth of sanding.

 

Good info. I'll check mine Thanks.

 

I'll give it a try. It would be nice to smoke my old man's Outlander 800 with mine. Even though I outweigh him and have a winch and skid plates on. heehee