Chromed Spiked Cone Air Filter From Suzuki M109 - C800 Conversion

If you search "air cleaner kit M109" on Ebay, you will find the kit I have used for this modification. I have done it slightly differently to those who have gone before me, so I thought an independent write up was in order. Firstly I bought this kit because it was cheap at £128.00 delivered to the door from the USA but also because it has two complete filters. I have at present only installed the active filter to the right side of the bike but in time I will install the second filter as a dummy on the left, which should make the bike look amazing.

The kit comprises of 3 main parts that will be used on the right side of the bike



The first thing I did was to cut off the lug pictured below, this ideally needs to be removed as it will hit on the head when fixed in position. It is very easy to cut off as this kit is chromed aluminium.



Next I drilled 2 holes to except the air temperature sensor, again very easy as this is aluminium



Here you can see it fitted.



You will need to increase the external size of the connector that excepts the hose for the PAIR valve, as the M109 has a smaller hose. All I did was to use 4 short lengths of heat shrink over each other for a perfect fit.



The next issue you will come across is that the above part is slightly smaller than the air tube that goes up under the tank that it connects too. If you have a fat rubber band such as the type used for pegging down whilst camping you will use one of these. However I did not and couldn't find anything suitable, so I made a gasket to assist in the fit.
Necessity caused me use use a bit of ingenuity on this one and make my own gasket/seal. All I did was cut a piece of rubber matting approximately 5mm x 10mm and then wrapped it & subsequently joined it together with rubber heat shrink.
Gotta be honest, it was a bitch to get it all in place but did make for a nice tight fit & seal, which you do need



My next issue was how to mount it. Previous modders have used a mounting hole at the bottom of the head but I decided not to use it as this is far to visible for me and I wanted to make less of a feature of the mounting. I decided to use the two mounting holes at the top of the heads as this would be far less visible to the eye and probably more rigid due to how short the mounting brackets are.

Firstly I cut two short lengths of metal and did a mock up with a spacer that was in the kit, to see how it would hold up. I did have to bend the metal bracket afterwards to make it fit properly but that wasn't an issue.
Here are 2 pictures of the brackets before they were cleaned up and sprayed black.



As you can see from this mock up, it is much tidier to go to the 2 mounting points at the top of the head, rather than the single mounting point at the bottom of the head



Here is a close up of the filter with the mounting points I used.



And a few more pics from different angles.

















I will shortly be fitting the spare filter from this kit as a dummie filter on the other side.

Hope this helps anyone wishing to do this mod & if I can be of any help with any queries, please ask.

Cheers Dave

Looks brilliant Dave and for that price an absolute bargain Excellent write up as per usual are they black chrome ? some pics look like silver chrome and some black chrome :what1:

Cheers Sim, they are all chrome mate. I think its just my camera and reflection that's making some look black & some pics chrome.

Your bike truly is looking ace now, Love it. Thanks for the detailed instructions

Thanks Joe, I am really happy with how she is turning out. Still got lots I want to do yet though.

Excellent write up Mr I, great job done as usual & expected. Your bike is totally smoking, you and

Great idea to run the holding brackets to to the top holes rather than the bottom one, much cleaner looking. Can't work out why it wasn't originally done like that when this mod was first thought of?
Can't wait till you do the dummy one on the other side, that will look absolutely brilliant & will be yet another first for suzuki800.com.

Thanks Crash, much appreciated

When you look at how this mod was originally done, which to be fair was inspirational and risky to be the first modder & how I have done it, my version is much cleaner.

Original Mod



MY Mod

Mr Intruder wrote:

When you look at how this mod was originally done, which to be fair was inspirational and risky to be the first modder & how I have done it, my version is much cleaner.

Agreed It's the Rolls Royce of M109 air filter conversions for sure

may be silly but is it possible to fit led lights in the cone be able to do it on the dummy side but could you do it both sides ? would look frickin nice

Not so silly Morgan, I have already thought of it & it is very easy to do with this filter. I should have it done by the weekend.

Good thinking Morgan and Dave, that would look very cool indeed.

Dave that looks bloody brill i've been looking at these for a while now was'nt brave enough to take plunge will have to seriously think about it now you've shown the way again would i need to rejet if i fitted one of these??

Excellant as usual Dave,those white led,s look well,they sure stand out.Going to clean my bike tomoz now,yours puts mine to shame.nice one m8.Dave are you going to depair or just blank the pipes?.

smart wrote:

Dave that looks bloody brill i've been looking at these for a while now was'nt brave enough to take plunge will have to seriously think about it now you've shown the way again would i need to rejet if i fitted one of these??

Thanks for the nice comment.
This is a very controversial subject, where many opinions come into play but the larger group of opinions would say that in an ideal world a re-jet would be in order but as long as you are adding only the hi-flow filter & are still running a stock exhaust, your bike should be absolutely fine.

alfie92 wrote:

Excellant as usual Dave,those white led,s look
well,they sure stand out.Going to clean my bike tomoz now,yours puts
mine to shame.nice one m8.Dave are you going to depair or just blank the
pipes?.

Cheers Alfie, much appreciated mate.
I will try to move the PAIR valve to an alternative location if I can but I have not looked into it yet, so I do not know if that is a reasonable train of thought or not. I will de-pair if I have too, simply as I need the location to mount the dummy filter.

Just shove it under the tank Dave,this stops any FI problems showing up aswell.Then if you go for the 109 bike in the future it will be easier to put back.

Yeah I was thinking along the same lines & I will never buy a 109.

fat intruder wrote:

may be silly but is it possible to fit led lights in the cone be able to do it on the dummy side but could you do it both sides ? would look frickin nice

Just done a mock up on the work bench of this idea with my spare filter & the 24 LED strip I used really glow out of it very well, as I suspected it might. I have taken photos in different lighting conditions to show how well this works.
Guess what I will be doing properly this weekend.

I'm liking it !

Glad you got around to it dave, the ride is smoother to. Took mine out last Sunday for a blast but I must say that you've done a brilliant right up

Cheers guys.
The good thing about these filters is that the are red, so putting a 24 red LED strip inside really helped it glow in a big way.
For the money spent this has gotta be one of the best mods I have done as far as looks go.

That looks absolutely amazing Mr I, almost like it is on fire . I wonder how long it will be before lighting up this kind of filter from the inside rather than the outside becomes a common mod. Not long me thinks

Thats gotta be yet another first for suzuki800.com

Looks brilliant Dav,be careful of your mates though (red lights facing forward.)Take it you are not going to progress to a 109 then.

Might be worth putting them on a switch

alfie92 wrote:

Looks brilliant Dav,be careful of your mates though (red lights facing forward.)Take it you are not going to progress to a 109 then.

Good point on the forward facing red light Alfie, I will scratch that idea. As for the 109, never!

looksg ood lit up dave pic another coulor and your of on your next mod

Yeah I might try one of my old blue LED inside it, as reed facing forward is a bad idea. That may create a green glow. Either way if I do add an LED to it, I will put it on a separate switch.

Dave, I've got one of these now, Have you sprayed your filter with K&N filter oil or is it not necessary ?

If anyone wants one of these filters at half the cost of the kit PM me as I'll only be fitting one.

Sim, Mr I is off Line for a few days while he is in Europe tramping in his truck, he will not be back in the UK until the end of the week, so he might not respond to your message straight away.

OK Cheers Crash Your in charge till he gets back then

Sort of

simbo wrote:

OK Cheers Crash Your in charge till he gets back then

captain crash wrote:

Sort of

Thanks Crash, good job done mate.

simbo wrote:

Dave, I've got one of these now, Have you sprayed your filter with K&N filter oil or is it not necessary ?
If anyone wants one of these filters at half the cost of the kit PM me as I'll only be fitting one.

Probably doesn't need it Sim But I did give it a light spray over to be sure.

Welcome back Dave, Is the air flow sensor necessary or can it be removed ?

Cheers Sim, good to be back on home soil.
It's not an air flow sensor, it is an air temperature sensor. Ideally this should be fitted & is very easy to do as it is very soft metal.

Mr Intruder wrote:

it is an air temperature sensor. Ideally this should be fitted & is very easy to do as it is very soft metal.

Hmmmm Mine fell off the seat today and I stood on it Does anyone know where I can buy a new one?

You require part # 13650-41F10 Here is one link I have found at £41.57, although I am sure there are plenty of others LINK
See how your bike runs without it, might be fine?

simbo wrote:

Hmmmm Mine fell off the seat today and I stood on it

Oh bugger, thats crap

Cheers Dave I'll give it a go without first and see what it's like.

Quick update, I've sold the spare chrome filter.I also ordered a air temp sensor for an sv650 which looks identical to the Intruders

I've noticed in the past that a lot of sensors and plugs look same on the sv as the Intruder.

I remember someone needed an o2 sensor and sourced it from a completely different Suzuki bike range. Makes sence really for suzuki to have as many parts that are as cross bike usable as possible. good point tho simbo for members to remember to look at other suzukis when they need a part and then just cross reference the part number to be sure it is the same. good way of keeping cost down often

I fitted mine today I've not painted the brackets yet, I'll do that when the new air temp sensor goes on

Top notch job done there Simbo, looks great

Definately a lot better securing the filter to top bracket holes rather than the bottom one. I love the way you guys work together and make things better

You have done an excellent job Sim, very tidy mate and at that price it feels nicer on the wallet too & Kerching!

Looking neat,looks like it is the way to go.

I've added a little finishing touch to the air filter I ordered two chromed aluminium skull dust caps the other week and ended up getting two packs of four, So when I had a minute at work today, I decided to drill the threaded hole for the valve a little wider so they fit over the bolts holding the filter on, A blob of silicone gasket glue and hey presto the ugly nuts have gone.

nice work sim i new there would be skulls on the way but a real tidy placement good job mate looks great keep em comeing

Like it

Its always the little touches that make the difference

great looking mod sim excellent job

Hi guys fitted the spiked air filter



looks great, only trouble is engine runs shite looks like i need to rejet missfiring & back fireing presume its running lean
any idea's which jet kit & where from

Surprised that you are having an exaggerated running issues when only the filter has been installed due to you still running the stock pipes. Looks bloody great by the way.

Every bike can be jetted differently, even identical ones. Your setup will require something like this, either a 150 or 155 main, 37.5 pilot jet, dyno spring, dyno needle on 3rd notch, mix screw at 2.5 - 3 turns. Don't quote me though, just a guess.