Ignition Cooler (by Reese Crenshaw)
This mod was obtained from Dirt Rider Magazine and is used by Guy Cooper
according to the article. I have a 94 600 FC (2 SEM ignitions previously
died before this mod was implemented in the summer heat of Redding CA) ,& and
a 98 FS 600, and have improved upon the technique. See the attached photos,
in no certain order, as I explain how & what to do. The goal is to vent the
head through a mini Uni Pleated Filter situated in the left side airbox (see
photo), draft the ignition as much as possible into the airbox through the
fitting that used to be used for the head vent, and provide a level of confidence that water & dirt will not enter the ignition cooling system/air
Look at the photos and you can see the basic set up. 1/2 inch heater hose,
with a disconnect in the midde, is used to route cooling air to/from ignition
cover. Also, although you can only see the tubing in the photo, there is an
addition uni pleated filter installed inside the airbox as a last catch (in
case an upstream leak past a filter or fitting develops) before the ignition
cooling air gets to the carb. The inlet filter for the cooling system is
simply a sock filter situated up in the frame as high as possible (see photo).
Fig 1: General view .
Take great care selecting a drill bit size and 90 degree fitting for the
ignition cover vent. modification. Practice on a piece of plastic before
drilling your cover. You want to drill the hole, then thread in the brass
fittings into the plastic. Screw in just far enough, then use silicone to
seal the threads inside & out. You will have to find some adapter hoses to
connect up from the brass fitting to 1/2 heater hose.
Fig 2: Detailed hoses
Fig 3: Detailed
view (Plastics on board).
When connecting the tubing to the air box fitting, use a 1/2 " 90 degree
plastic fitting just before the connection to avoid an excessive bend on the
tube & help tuck it out of the way.
Fig 4: Valve head &
air filter (I) .
5: Opposite view
Drilling the plastic air box bottom and routing a tube with filter from the
valve head into the left side air box is self exlanatory, as is the inlet
tubing with filter for the cooling system. See photos.
As the last bit of insurance, select the appropriate size hose with a
pre-bent 90 (old emission tubing from a street bike), adapt a mini uni or
sock filter on one end, and stick other end into the hole inside the airbox
used for the head vent (now ignition vent). Use silicone in the hole to hold
the assembly in place if it's not as tight of fit as you'd like. See photo.
Fig 6: Silicone .
Fig 7: Air view showing
another tech mod .
This mod works, and is the single reason I have decided to keep the Bergs.
Let me know if there are any questions.
I have another mod for aluminum radiator guards & cooling fan, and parallel AC/DC if anyone is interested.