Suzuki M109 air filter cone conversion

After reading about another member toying with air filter mods and options, I went on a snoop to find options and found an interesting one for the C or M 800, the only trouble is these kits come with two of everything because the M109 has two filters, but if two members wanted to do this mod, It would half the cost to a more reasonable £75 ish which is not a great deal more than a K&N.
The kits come in black or chrome from UK suppliers on Ebay but cheaper from China and most probably the same thing.
Here's how it looks on the M800

And on the C800



First off the adapter is slightly smaller than the rubber boot it connects to under the tank, so needs enlarging with some rubber or similar,


This is what they did

making a better fit in the boot

Then they ground off the lug which is for the 109 and not needed for our bikes, and drilled it ready to take the air temp sensor

Here it is with the sensor fitted

Then they bent the bracket to fit the 800, it comes with the kit

Finished result as above, Not a bad mod considering the kit comes with two of everything and could possibly half the price, for the kits just search Suzuki M109 air filter kit on Ebay and quite a few come up over here but might be cheaper in the US
Happy modding

Ah I've just noticed the kit only comes with two brackets but they should be easy enough to make.

That is a brilliant fin Sim, I may very well consider this for my bike.

It looks good on either bike for sure (imo) I'd have definitely gone in this direction had I not ordered the Thunder mfg one, and saved myself a few of the hard earned £. ah well, hindsight is a wonderful thing

Now that is very very clever indeed

Thanks for the heads up on this M109 air filter conversion Sim, I have just ordered the black and chrome ones from American Ebay.
Really looking forward to these arriving as the black and chrome looks beautiful.

They do look very nice indeed I'd have done that myself had I not already ordered the Thunder one

Oooo now that is very pretty, we will look forward to your own writeup of fittment and pictures Dave

Was it expensive for the two of them & what are you going to do with the spare one?

Yeah I will do a write up when I do get it Crash & it cost £128 delivered, so that was good. Not sure what I will do with the other one to be honest. I may mod the spare one up ready for fitting by someone else but will probably just keep it on the shelf for the time being.
I know this might sound crazy but I am thinking of fitting it on the other side of the bike. I think that could look really cool.

Mr Intruder wrote:

I know this might sound crazy but I am thinking of fitting it on the other side of the bike. I think that could look really cool.

Thats a totally smoking idea, I love the sound of that

That would look absolutely amazing ! there's not much going on with the left hand side of the bike for starters, good idea

Just checked USPS and my M109 cone air filters should be ready for picking up over the next day or so, as they cleared UK customs on Friday afternoon. Hoping to get the one that will be working fitted this weekend and the dummy one fitted over the next week or two but I will have to de-pair the bike first as the pair valve is in the way of the dummy filter.

This is going to look amazing when you have filters fitted on both sides even if one is a dummie one. Good shout dave, I will look forward to this as I have never seen anyone do that before.

This will be another first for suzuki800.com

Yeah Just had a knock at the door and Mr Postie was there to hand me a box with my M109 cone spiked filters in.
I thought it was rather heavy and joked to the Mrs that they must have sent me a couple of bricks just for the crack. I opened it up and was really shocked at the quality of this product. I thought it would be made of plastic like the Intruder stock filters but no, it is all metal. A very good quality chromed billet aluminium. Happy days, I will look forward to putting these on.

PS, As it wasn't expensive there was also no duty to pay and because it came via USPS the UK post office charges were also covered.

That sound like a real bargain then, £128 to the door for 2 of them from state side can't be beaten surely if they are that good. Look forward to your install and write up Dave

It sounds great Dave I can't wait to see them Very fast delivery too ! I'm still waiting for mine

wow dave,they look awesome. cant wait to see them fitted.

They will look boss on your bike Dave,be nice to see them fitted.

Cheers guy, I will have one fitted this weekend for a fact and if time permits I will de-pair and fit the other one on the left. Probably be the following weekend for the 2nd one though.

I might well go for this myself once I see how they look on your bike. Are the left and right parts identical?

Yes

Damn things move quickly on here, if i knew you was going to order one so soon dave i would'nt have ordered mine and we could have shared the cost. mine came back on monday going to fit it tomorrow

I need them both lez as I will be putting a dummy one on the left as well

no pronlem Mr I, sold it to my mate but here's one i did earlier. sorry no fitting photos went on so easy did'nt have time.

Looks great lez
How did you get around the size difference between the adapter & the boot, what did you use?
How did you bolt it to the bike head, did you bend the brackets it came with or fab your own?
Any issues with fitting the temp sensor?
What did you do with regards to the PAIR valve hose?

With the adapter and boot i used a bungee you use for tent pegs, perfect fit, its a bit fiddly but a bit of patience it slid into place when fitting it  together.

as for the bracket i fabricated a "v" shaped bracket i had hanging around in the garage, didnt use the ones that came with it, they seemed a bit to much like hard work(being a trucker dave you'll understand).

no issues with the air temp sensor, the metal is quite soft so made for easy drilling as with the holding screw just dill a hole slightly smaller than the screw thread and it cuts itself in.

right with the pair valve hose, on our bikes its bigger than the stem on the adapter so i cut about 4 inches of insulating tape and wrapped that around the stem on the adapter to make it air tight.

you will also have spacer's which came with the filters, i cut one in half to keep the bracket off the engine
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Edited by Admin to remove picture links that had been removed, moved or deleted by poster from their Photobucket account

Looks great Lez Does it give the bike a throatier induction roar ?

dont know yet sim have'nt gone out on the road with it yet, have had it running in the garage just to see if it was sucking in any air from the adapter to the boot but all seems fine

Fantastic lez, that helps out a lot mate.
Off down the camping shop for me then, I was tinkering with different ideas for the gasket but yours is better than the way I was thinking. I will also fab up a bracket rather than use what they supplied & as with you, I will see what the end of the garden has to offer for that.
Cheers mate, looks ace .

doobie wrote:

as for the bracket i fabricated a "v" shaped bracket i had hanging around in the garage, didnt use the ones that came with it, they seemed a bit to much like hard work(being a trucker dave you'll understand).

I know what you mean Lez, my favourite saying is "I became a Trucker because it's better than working for a living.

Nice to see a member fitting one of these, looks fab lez

cheers cc

thats the same saying as me dave......hahaha.....if i can help you out any more let me know.

good job lez looks nice

How you getting on with your one dave, I noticed in you "white light" thread that your stock one had been removed. so I presume your at it this weekend?

I am making some brackets at the moment as I want to support the filter from a higher point as I don't want to see the holding bracket. Easier said than done, believe me. I have just launched my iphone accross the workshop in temper, as I keep getting the angle wrong. I also couldn't find anywhere that sold the rubber bands that are used to make the filter fit the stock outlet yesterday & don't have time to order some, so I had to make a gasket, you will be shocked at how I did that but ingenuity always comes into place when I am backed into a corner on time. I will hopefully put a full write up with pics and my how too on site tomorrow.

well just took thunder nuts out for a pootle and am pleased to announce that nothing fell off, as for the throarty roar of sucking in air could'nt really hear anything over the noise of my pipes. but i will say this,its like tunes...makes it breathe more easily and its cured my back fire.....(for now)

These look pretty awesome, do you reckon these would fit on a 97 marauder? changing filters and such is not something Ive looked into, until seeing these

Yes they would fit Mark, with some modification. read what is in this post higher up mate, dave is also fitting some at the moment & he will do a walkthrough as well.

Aaah fantastic thanks for that, will look at ordering when I get paid then. didnt want to order if they wouldnt go, its good to know what you can get away with first.
Wish I had found this site a bit sooner. would have looked at starting doing work on it sooner then! only downside another mod I know can do means another to the list of parts need to buy. the list keeps getting longer!

Get used to having no money, that girl of yours likes to be treated

haha too true, I took out a 5k loan to buy bike and do test at start of year, somehow I have none left and skint again!

anyone has a spare cone spike filter to sell?

Simbo did you use a tent peg as shown in the picture above by another rider? I'm having a little trouble getting one to fit at my local shops, if you also used one of those I will order one online or did you use something else?

Hi Ken, Yes I used a tent peg rubber, I got them off Ebay, They weren't as wide as those in the picture so I used two side by side.

Just what I needed to know, thank you.

Thanks for this excellent instructable with the pictures and tips, most helpful whilst fitting mine today.