canadaler Posted January 8, 2013 Report Share Posted January 8, 2013 Hi all...I'm the recent owner of an '85 Cagiva TR350 which is missing the air filter. I can buy filter foam to make up another one but I'm a bit confused as to where it actually sits in the air box. The parts manual shows a screen and a flat, rectangular filter, which must sit somewhere in the air box, but there seems to be no tabs or flat surface for such a filter to seal against or anything to hold the screen and filter in place. There is some mystery nut shown on the parts diagram which is floating in the air and not connected to anything. It would make sense that the screen goes in against the filter then is bolted down into place to secure it...but no bolt is shown in the diagram and I can't find any evidence of one having been in the air box...very confusing. Anybody out there have or had a Merlin that can shed some light on the situation? Oh...It's also missing the connector boot between the carb and the air box. From what I've measured and seen it looks like a boot from a late model Sherpa might fight. Considering the Merlin heritage and use of some other parts from the Sherpa I'm guessing maybe the boot is the same as well....??? Quote Link to comment Share on other sites More sharing options...
woody Posted January 8, 2013 Report Share Posted January 8, 2013 I'm fairly sure In Motion have these as I'm also fairly sure I had one to try in an Armstrong. I think it is a filter with hose attached but that's not what you're describing from the parts book. Have you tried In Motion? Quote Link to comment Share on other sites More sharing options...
ducman Posted January 8, 2013 Report Share Posted January 8, 2013 Try Morro in Varese,shure they can help you for parts for the Cagiva/Merlin DG 350. Cheers:Mike Quote Link to comment Share on other sites More sharing options...
canadaler Posted January 8, 2013 Author Report Share Posted January 8, 2013 I checked the In Motion site and didn't find anything listed for the Merlin air box. Here is a screen shot of the parts manual page for the air box: Parts 1,2 & 3 are the lid to the box (which I have) 4 is the mysterious nut that doesn't seem to bolt to anything, 5 looks like a screen and 6 is the filter element (foam I assume.) Intake air enters at the rear of the box, travels down and forward into the bottom of the box then up to the carb boot. Somewhere in between that is where this rectangular filter is supposed to fit...I think But as I said there seems to be no flange or area to "seat" a filter to, nor anyway to secure it in place...so I'm a bit lost. Maybe I should just forget about trying to figure it out and make a flange mounted "sock" filter to it...? Quote Link to comment Share on other sites More sharing options...
b40rt Posted January 8, 2013 Report Share Posted January 8, 2013 Maybe a "5" below the foam as well ? Quote Link to comment Share on other sites More sharing options...
woody Posted January 9, 2013 Report Share Posted January 9, 2013 I see what you mean - maybe the filter In Motion supply is a replacement that does the job as I'm sure that the one I tried for my Armstrong is one that they sell for the Cagiva 350 - but my memory is lousy Maybe you could use a 340 Bultaco type filter as that is a round filter with integral hose, the filter sits inside the airbox and the hose is pushed through the hole onto the back of the carb, the hose has a groove that seals in the filter box opening to the carb Give In Motion a ring as they may know how to get around your problem. Not everything they stock is on the website. Also, one of the forum members owns a Merlin / Cagiva so expect them to chip in when they see this as they are bound to have an answer Quote Link to comment Share on other sites More sharing options...
canadaler Posted January 9, 2013 Author Report Share Posted January 9, 2013 Maybe you could use a 340 Bultaco type filter as that is a round filter with integral hose, the filter sits inside the airbox and the hose is pushed through the hole onto the back of the carb, the hose has a groove that seals in the filter box opening to the carb I've taken a look at that and it looks like it might have a chance of working. Closest so far anyhow. I'm beginning to think that the parts manual drawing is more of an "artist's concept" than engineering drawing! Quote Link to comment Share on other sites More sharing options...
canada280i Posted January 10, 2013 Report Share Posted January 10, 2013 4 bolts to 12 which looks like the bolt that holds the back of the filter box either to the frame? or does it go through the rear fender? Quote Link to comment Share on other sites More sharing options...
b40rt Posted January 10, 2013 Report Share Posted January 10, 2013 4 bolts to 12 which looks like the bolt that holds the back of the filter box either to the frame? or does it go through the rear fender? there are a few 4s to choose from ! Quote Link to comment Share on other sites More sharing options...
canada280i Posted January 10, 2013 Report Share Posted January 10, 2013 Bugger me...so there are! That is what happens when you try to respond at 6am in Canada when its -10 outside Quote Link to comment Share on other sites More sharing options...
canadaler Posted January 10, 2013 Author Report Share Posted January 10, 2013 there are a few 4s to choose from ! But only one has no matching bolt. Quote Link to comment Share on other sites More sharing options...
canadaler Posted January 12, 2013 Author Report Share Posted January 12, 2013 Perhaps some progress. I found this which is for an '88 Gallach Replica, but it certainly looks like it has the same boot as the late model Bultaco and that filter configuration definitely looks like it would fit in my bike. I've sent off a message to the vendor. Quote Link to comment Share on other sites More sharing options...
canadaler Posted February 1, 2013 Author Report Share Posted February 1, 2013 Just a follow up here for future reference. I purchased a filter/boot combination from GP Recambios in Spain that was listed for the '85 Gallach Replica. It fit but I ended up modifying it a little. I separated the filter element from the boot then made a wire cage to go inside the filter and a spring assembly between the filter and back of the air box to push the filter up against the boot via removable spring. Now I don't have to struggle taking the boot off and on to clean the filter. Also should mention that the folks at GP Recambios were great to deal with and prompt shipping of the item from Spain to Canada went without a hitch. Quote Link to comment Share on other sites More sharing options...
motoviking Posted April 27, 2015 Report Share Posted April 27, 2015 Hi Canadaler, I just joined the site and own an 82 Cagiva DG3.5 The airbox drawing looks just as my bike. I have all parts except the filter element and screen. #3 cover has a stud welded to it which looks like has been cut off of mine. Maybe that floating nut went on the stud, but I dont get the scheme. Looking into the box I also have seen no provisions for retaining the element. I would be interested in your solution and will check out the supplier you mentioned. My airbox to intake boot is torn and I doubt I will be able to find one so may change the entire approach. Also, my bike seems to run ok however its surges and power delivery is abrupt. Im pretty certain the engine, carb ignition etc are completely stock. It doesnt seem to want to go slow like my well mannered TY Yammie. It's like it needs more flywheel. Only way to get smooth drive at slow speed is brake dragging and clutch slipping. Any thoughts regarding this ? Thought maybe I could retard the ignition timing a bit to tame it. Do you have timing spec and process by chance ? Any idea where a parts manual and owners book can be found ? Thanks for any help ! Quote Link to comment Share on other sites More sharing options...
gasgas249uk Posted April 27, 2015 Report Share Posted April 27, 2015 http://www.retrotrials.com/merlin-fius-parts-book.html Quote Link to comment Share on other sites More sharing options...
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