Arlen Ness Big Sucker air intake

When I bought the bike the previous owner had modified the intake and exhaust slightly and installed a K&N filter. Kind of a low grade Stage 1 upgrade I guess. Because of this the bike exhibited the behavior of running lean. I decided to add a Lloydz VFC-III fuel controller to remedy this. I decided to look at aftermarket intakes while I was at it. For the V92TC you pretty much have three choices; one made by Lloydz ($$$$), one made by S&S, and the Arlen Ness Big Sucker.

Due to price I decided to go with the S&S or Big Sucker. I happened upon a "never used" Big Sucker on Ebay and got a good deal on it. I also found out the Big Sucker kit is pretty much an older factory air box (P/N 5432506) with K&N filter PL-1598. The K&N filter in the kit even had a Polaris part number on it. There were a couple of these factory air boxes on Ebay.

The Big Sucker kit.

The instructions are good and the installation is straightforward so I'm not going to cover every step.

After removing the seat and gas tank the next hurdle is removing the factory air box. The only way to remove it in one piece is to drop the motor so it has to be destroyed and taken out in pieces. I cut away some plastic so I could remove this sensor. I used a chisel to break the air box apart at its seam as much as possible then used a cutoff wheel to finish the job.

I was able to get it out in three major sections.

When someone posts in the forums about a poorly running motor they are often advised to check the rubber caps on the vacuum ports. Here is why. Believe or not, the cap on the right was still sealing the port, but barely.

The sensors are transferred to the new air box, the filter is attached, and the unit is bolted into place. The kit uses hex-head screws to attach the air filter to the box but I substituted Phillips-head screws. The new filter setup is pretty much hidden.

Removing the old air box cleans up the front of the motor. The filter is hidden by the gas tank.

On an unmodified airbox this is where the air enters, and it is pushed up against the down tubes.

E-mail me