Gio Monster Air Filter Mod

Weldangrind · 09-30-2014, 02:13 AM

I did this mod several years ago, before I joined this forum. Since I was working on the quad this past weekend, it seemed a good time to share the upgrade.

The stock airbox was awful, and it was very difficult to get to. The entire front half of the body had to come off for access, and that means the filter will be neglected.

I used the stock boot from the original airbox, and I inserted a piece of ABS pipe and clamped it. I cut a hole in the plastic under the seat, brought the ABS through the hole and clamped a Uni pod filter onto the pipe.

I also cut up an old water jug and zip tied the plastic to the frame to act as a splash shield.

The filter has always been dry since the mod.

Weldangrind · 09-30-2014, 02:15 AM

Since I had also swapped a Monster muffler onto the quad, I drilled the main jet out to a 117. It starts and runs great, although I might have gone a little far with the main jet size. I'll try another one eventually.

Weldangrind · 10-27-2014, 12:57 PM

I checked my spare GY6 carb, and the stock main jet is 103. I have some spare jets around from Pastor Jim's 250 Saga (that he sold), so I'll experiment and see what works. I'm guessing that a 110 will do the trick.

Weldangrind · 11-24-2014, 11:53 PM

I popped a 110 into the carb tonight. I'm looking forward to trying it.

BLACK DEATH · 11-25-2014, 09:19 AM

Nice mod there.... But where did you find preside drill bits for the carb jets?

Weldangrind · 11-25-2014, 12:46 PM

I use a numbered and lettered drill bit index, which is easily found at Harbor Freight. Just let Google do the math for you.

For example, a 30mm Mikuni comes with a 100 main jet, which means 1.00mm. 1.00mm is really close to 0.040", which translates to a #60 drill bit.

To drill out a main jet to something near 110 (or 1.10mm), select the #57 drill bit, which is 0.043", or 1.092mm.

It's much faster than buying new jets, every time you wish to experiment. BTW, I already had a numbered and lettered drill index, for use with drilling holes properly for tapping. The carb jet use is just a bonus.

09-30-2014, 02:13 AM	#1
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Gio Monster Air Filter Mod I did this mod several years ago, before I joined this forum. Since I was working on the quad this past weekend, it seemed a good time to share the upgrade. The stock airbox was awful, and it was very difficult to get to. The entire front half of the body had to come off for access, and that means the filter will be neglected. I used the stock boot from the original airbox, and I inserted a piece of ABS pipe and clamped it. I cut a hole in the plastic under the seat, brought the ABS through the hole and clamped a Uni pod filter onto the pipe. I also cut up an old water jug and zip tied the plastic to the frame to act as a splash shield. The filter has always been dry since the mod. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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09-30-2014, 02:15 AM	#2
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Since I had also swapped a Monster muffler onto the quad, I drilled the main jet out to a 117. It starts and runs great, although I might have gone a little far with the main jet size. I'll try another one eventually. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

10-27-2014, 12:57 PM	#3
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I checked my spare GY6 carb, and the stock main jet is 103. I have some spare jets around from Pastor Jim's 250 Saga (that he sold), so I'll experiment and see what works. I'm guessing that a 110 will do the trick. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

11-24-2014, 11:53 PM	#4
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I popped a 110 into the carb tonight. I'm looking forward to trying it. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

11-25-2014, 09:19 AM	#5
BLACK DEATH Join Date: Nov 2014 Location: South texas Posts: 51	Nice mod there.... But where did you find preside drill bits for the carb jets?
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11-25-2014, 12:46 PM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I use a numbered and lettered drill bit index, which is easily found at Harbor Freight. Just let Google do the math for you. For example, a 30mm Mikuni comes with a 100 main jet, which means 1.00mm. 1.00mm is really close to 0.040", which translates to a #60 drill bit. To drill out a main jet to something near 110 (or 1.10mm), select the #57 drill bit, which is 0.043", or 1.092mm. It's much faster than buying new jets, every time you wish to experiment. BTW, I already had a numbered and lettered drill index, for use with drilling holes properly for tapping. The carb jet use is just a bonus. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0