"NEW" Chuckster backing plate (Update Pg 6)

[rewindgy]

Okay, so now we are gettin technical! So, for stock dog bowls you gotta drill more holes. And if you want to put it back to stock for what ever Government reasons ( TBA) you can't just unplug everything and re-plug it in. At least with the marbles you can remove them if needed!

[cactusjack]

Alright - so I decided what to do with the crankcase breather hose, which was homeless after the 7" air cleaner conversion.

I went to ACE Hardware and bought a 3/8X1/8 barbed elbow, the 1/8 refers to MPT or "male pipe thread". Should be available at many hardware or plumbing supply stores:


Then I drilled a 5/16 hole strategically placed to sit right in the opening of the crossover tube:


I then used a 1/8X27 NPT (national pipe thread) tap and tapped threads in the hole I just drilled and screwed the brass elbow fitting into it:


From the rear, it's positioned at roughly 9:00, but I have since rotated to about a 45 degree angle or approximately 7:00:


Here is the finished product, no more breather filter...and a much cleaner overall look:

[dkdixie]

Good job CJ!

Now, tell me what you plan to do, if anything, to the length of the idle adjustment cable?

[chuckster131]

Ok here is the deal ! I have about 10 plates machined, and what I'm going to do is go back and add the extra pipe tapped hole / drill the (2) holes for the idle silonoids as well to the one's I have left. So that will help add to the ease of the install.
If someone that has allready purchased one from me and whats the extra added holes I can swap that one out for the other.

Originally Posted by "dk dixie"

GOOD NEWS from Chuckster!

Just talked with Joe and he is going to do some redesigning on the backing plate.

First, he's going to offer two options, one using stock covers and the other, using exposed filter.

Secondly, he going to drill two holes for the vacuum lines. All user will have to do is run a bead of silicone around them on the plate. The existing little rubber grommets will help seal from the backside.

Third, he's going to look into drilling and tapping hole for the crankcase vent line. Will not be suppling the fittings but will tell you what you need if you want to go this route.

So, if you are looking to purchase you may want to call him or specify in an e-mail exactly how you plan to use the plate and what you want as options.

Joe thought he would have the updated versions ready in a week or so.....

[cactusjack]

Originally Posted by "dk dixie"

Good job CJ!

Now, tell me what you plan to do, if anything, to the length of the idle adjustment cable?

Nothing. It fits quite nicely into the slot made for it on my water pump cover.

[VulcanE]

CJ, what type / brand is your "waterpump cover"?

[cactusjack]

Originally Posted by VulcanE

CJ, what type / brand is your "waterpump cover"?

It's genuine Kawasaki. I ordered it from Bike Bandit for $35 or something. Takes 5 minutes to install, only 2 bolts.

[badnomad08]

I just wanted to say THANK YOU to everyone for posting so much info about this mod. After all of the fine tuning is done (and momma says it is ok), I will definitely be ordering one. I do have to say that Chuckster is one heck of a guy for offering to exchange the "early" model plates for the "new" and improved version. I was wondering (Chuckster), if you have thought of offering a plate (even though it is not functional) for the left side of the bike just to keep things symmetrical? Thanks again everyone. Ride Safe!!!

[chuckster131]

I just might do that sometime in the near future... What I need to do for this to happen is have a 1600 here to make sure it is the same as the 1500, and then see what it will take to make that left side dummy plate.
If someone wants to make a pattern and also send some pics of the factory plate I might be able to desing off of that, or atleast know then if they are the same from 1500 to 1600.

Originally Posted by badnomad08

I just wanted to say THANK YOU to everyone for posting so much info about this mod. After all of the fine tuning is done (and momma says it is ok), I will definitely be ordering one. I do have to say that Chuckster is one heck of a guy for offering to exchange the "early" model plates for the "new" and improved version. I was wondering (Chuckster), if you have thought of offering a plate (even though it is not functional) for the left side of the bike just to keep things symmetrical? Thanks again everyone. Ride Safe!!!

[borto1990]

if you need a 1600 to measure joe, I'm still hoping to be there next sat still so you can get what ever you need off my bike if you want...

[reaper]

Originally Posted by "dk dixie"

If you are planning on purchasing Chuckster plate AND plan on using stock covers, you will have to do one least one modification. That is drill mounting hole (and tap 1/4-20 if you want) for the cover rod.
The plate in designed to be used with exposed filter, and I'm sure it works fine, but I wanted to use stock covers....so, drilled hole 5/8" below existing mounting hole to give clearance for the gas tank. With existing mounting hole the tank will hit the stock cover.

Also, the two center located vacuum tubes can be pushed back and off to the right side but I think CJ's idea of removing and capping off at manifold is a better way to go.

I elected, for the present time, to pull the crankcase breather line up between the two cylinders, cut off about 15 or so inches, rerouted over to the left side and installed external small filter behind the horn mounting bracket.
Next time I'm by a Harley dealer, will purchase one of their small breather filters which are only about an inch or so long. Or, I'll let CJ tell me what size tap and drill to use and thread the bottom of the plate.

Would you post some pics when it's done

[nomad]

chuckster, you are da man!! good job! :)

[chuckster131]

That would be great! Maybe we can come up with a design..

Originally Posted by borto1990

if you need a 1600 to measure joe, I'm still hoping to be there next sat still so you can get what ever you need off my bike if you want...

[cactusjack]

Joe, I'd be willing to send you my 1600 left side backing plate, if that would help. I would need it back, though.

[borto1990]

ok, maybe i just got lost.. if we put the plate on the right... and the tubes and everything can stay intact.. why do we need a plate on the left side? since the left side isn't used anymore, isn't it just a dummy plate the way it is. oh wait.. is this just for people that want k & n on both sides? think I got it..