Figured this was long overdue
This install is on my 2000 ACE 750 but many of the ideas and concepts will work on the Spirit as well. Thanks to Aced it, Custom Crzy and Swilly who all went down a very similar path before me and provided some of the preliminary information I needed to work out my installation.
NOTE: You WILL have to re-jet after this modification!
plastic sheet or cardboard for a template
screws or pop rivets
jigsaw with metal cutting blade
drill and some bits
Considerations before you start:
The faux cooling fins on the front cylinder of the ACE do not continue around behind the stock air box so if you plan to go with a smaller filter you will need to consider how you will cover up this gap in the fins. Many take a set of fins from the left side rear cylinder and modify them to fit the area but it does take some grinding to make everything fit so be forewarned.
Here is a link to the fin mod: http://whytlash.powweb.com/finmod/finmod.htm
Step 1: pick your filter. If you don’t want to do the fin mod noted above then pick something large enough to cover the missing fins. A number of people have installed an Edelbrock pro-flo filter but I wanted to be different and went with this oval filter that was originally designed to fit Weber carbs on cars like the Austin Healey. Note: there are 2 sizes of the style filter I purchased one is 7" x 4" which will not cover the missing fins and the other is 9.25" x 5.5" which is what I purchased. Be really careful with the sizing as this style of filter is available for Harley's but is almost always the smaller version so be sure to get measurements.
Whatever you choose, it is easiest to work with a filter that has a flat steel backing plate to allow modification to fit the rubber connector for the intake on the ACE. Here is the filter I chose:
Most filters will need to be modified to work on the ACE so to that end, I first made a template from plastic that matched the dimensions of the filter backing plate…. It’s better to toss out a couple of pieces of plastic if the alignment is off than it is to cut up your new filter incorrectly!
Once you start cutting on the actual filter there is no going back so think things through first!