Let us know how it all works out. I am getting the 135 from the dealer and give it a try. I am at about 600-1000 ft here so I should be good. i still can not get that freaking silencer out. I will do the air box mods and let y'all know how it goes.

 

How are you trying to remove the silencer? If you look at the muffler tip, it has that lip that sticks out wider than the muffler pipe. If you take a flat head screwdriver from the back and a hammer, you can tap it out of the pipe. After I figured out that the smaller diameter pipe you see inside the exhaust is actually welded to that wider section, it was a piece of cake...will take you 5mins if that. As for me, I'm around 500 ft and have done all the mods suggested except the airbox mod. Right now she runs great, but when winter hits (Ohio), I plan to reinstall the silencer to richen up the mixture a bit. After the mods, the B-inlaws Polaris Sportsman 400 can't even stay close enough to eat my dust!

 

Hi guys. New to this forum. Got any current pictures of the air box mods?

 

Installed the DJ 122 Jet
K&N air filter
Removed 1" from Metering jet spring

Results:

1) Cleaned sparkplug and started engine. What a difference! Didn't need to use choke.

2) Test drove and noticed that I went through the gears much quicker and consequently reached top speed in a shorter time.

3) Noticeable front end rise at each gear change (5 speed man)

4) removed spark plug; look good, maybe a bit lean.

Removed air box lid and re-tested.

1) Went through gears and reached top speed faster yet.

2) Spark plug apearance unchanged.

Modified air box lid.

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Couldn't locate any air mod pic's so I improvised.
Link to picture:

http://s151.photobucket.com/al...w&current=100_2346.jpg

 

Took it out for a real test drive at Greenridge State Forest. WoW! Like someone said earlier in this thread, it ran like a raped ape!!! The biggest and most welcome benefit is the increased mid range and top end power. For the first tiime, this machine pulls hard in fourth and fifth speed; very hard. Parts of the trail that previously required third speed I was able to do it in fourth and fifth, again pulling very strong. The power band has also stretched out. Certain parts of the trail I never shifted into fifth simply because it was still pulling so hard in fourth and was still building up steam. I was really sceptical about these mods but I can tell you, I'm speachless.

Modded the exhaust before this trip. I removed the spark arrestor and peaked inside the muffler with a flashlight. There is a chamber visible through the tailpipe. The exhaust passes through this chamber and then forward to a chamber in the center of the muffler and back through the spark arrestor pipe out the tailpipe. It would stand to reason that simply removing the spark arrestor would create turbulance and rob power. I installed a pipe to go in place of the spark arrestor tube to maintain a path of flow for the exhaust gasses. Doesn't sound any louder than before but I'm sure it increases flow to some degree which makes the other mod's work better which equals better performance.

Feels like a different machine! I quickly learned that faster is not always better. I found myself in a few emergency braking situations because the increased speed left me little time to react to unanticipated obstacles or overshooting a turn. I swear, I felt like the bike was taking me for a ride!!! I noticed that my arms fatigued unusally fast from trying to stay on when accelerating hard or traveling at higher than normal speeds with the tail end kicking left to right with the wheels spinning.

The plug looks a bit lean after a day of riding. Will go up one more jet size.

Thanks for everyone who contributed to this thread. I will post anything else that I learn in my quest for more power.

I'm afraid of what forty horsepower must be like. I think I'll wait awhile before getting that Outty 800R!

 

wow Chuck. you sound happy..lol [img]i/expressions/face-icon-small-smile.gif[/img]
I don't know yet if I will ever do my airbox....probably should since I doubt I ever will subject my machine to high water. I know I won't be removing my arrestor. How do you guys get away without an arrestor, or rather where do ya live that ya don't have to have for public land?
Funny thing about my ride is that I am unsure the jet mod will show me much difference to how it's been running. See the guy before me lost or yanked the needle jet and the machine gets all the gas it could ever want currently. I don't know what it equals out to but she sure ran strong even though it an automatic. Now I am somewhat leary that once I put it back stock with a needle jet it will be a dog. Maybe I should order up a few jet or the dynojet just in case. I have trip planned for up north in several week and it would suck if it runs like doodoo.

ps- oh now I see..your airbox mod is inside box. Snorkling height still all the same then right?

 

If you haven't done any of these mods I would highly recommend it. From everything I've read, these engines are detuned to meet emission and noise level requirements. To answer your questions, the snorkel is stock height but I don't go through water higher than my foot boards anyhow. The Eiger is by no means a "mudder". As far as the spark arrestor goes, who can prove that you don't have one? The trails are wide and dotted with campsites along the way. There is a far greater risk of a spark from a campfire starting a fire than one from my tailpipe. The factory pipe is a chambered muffler, not a staight through glass pack. I don't see any risk from a factory muffler.

 

Thanx Chuck,
Speaking of glasspack, I think I am going to screw up the whole idea of performance gains on mine as I plan to do a DIY noise suppressor during hunting trips. Far as I can tell by industry offerings like Silent Rider, and from talkin to people, all they basically are is a glasspack with a turned down tip. Supposedly all should be fairly ok in the power department if back pressure is kept to like under 2% (not that I have ability to measure such). Word I also heard is that a perforated pipe on inside forcing the sound waves to bounce around inside more works some pretty good magic without it becoming a full on secondary muffler.
Perhaps the end result will be that if I am jetted properly for down under a couple thousand feet in elevation without suppressor then it will be right on for higher up with the suppressor hooked on. Just hope it don't suck going up hills.

Far as mods, although I understand that aftermarket DJ kits utilize a softer but progressive spring to gain the results they were after, I went ahead and cut an inch off my original. It does seem quiker to the revs. Oh and even though they not really mods... I cleaned the carb, installed inline filter, and put an air filter on the carb ventline..lol
Next up is getting a needle jet back in there, changing oil over to the synthetic (JASO MA), and doing the airbox mod. Question: what comes stock in way of air filtration on 03' Eiger?. There is oiled foam installed now.

 

Sounds like you have the stock air filter; oiled foam. Are you running stock jets? The Quadworks kit comes with an assortment of jets, new needle and a K&N filter; the origional spring is used. I cut a little less than an inch off. As for hunting, the suppressor is a great idea.

 

Yes, is stock with 122 stock jet. I am running out of time and have to finalize my setup for hunting within the week. Worst case scenario after getting needle jet in would be that it is way too lean on a cold morning at 8k'. I am unsure if I can even obtain a few selection of jets local at this point tough. Think the dealers said they got to order them. I better get on the on the phone hu..

ps- Turns out the guy I have repair kit on order through has jets on hand.
So being I have no real mods (maybe the airbox drilling) and I want to be good upto like 8-10k' would a 128-130 jet sound suitable? I'd think the airbox and perhaps the suppressor at the higher elevation would make them mods a wash and be about like a stock machine if I do that size jet.