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NooBSchool: yanking an airbox without removing the engine.

Discussion in 'XJ Technical Chat' started by Marko, Jul 17, 2008.

  1. Marko

    Marko Member

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    Aloha,
    I was out at Danno's place yesterday, and we were going to be taking an airbox out of one of his parts bikes. Airboxes, as most here can testify, are notorious pains in the asses to remove. We managed it without removing the engine or shattering/cutting/breaking/otherwise-destroying the airbox.
    Here's how we did it:
    -Remove seat.
    -Taking the tank of makes it easier to see.
    -remove carbs AND carb boots.
    -Unscrew lid of airbox and set aside.(leave filter in. if you start smooshing the filter at any point during the process, you're torquing the airbox way more than necessary.)
    -Unscrew screws holding airbox in.
    -Remove the battery box AND corresponding electrical component holder on the other side.
    -Unbolt the clutch-cable bracket, and move the cable out of the way(make sure all other wires are out of the way.)
    -Push airbox down and forward.
    -Work Back end of airbox through the(if you're sitting on bike) Right side of the frame, while lifting up on front of airbox and move up/left
    -work back end of airbox through the left side of frame, while moveing front of airbox up/right, clearing the motor.
    -There will reach a point where it is slightly catching on the rear, but almost out. Slowly apply steadily increasing pressure.
    -Don't have face near front of airbox when it pops out.

    It sounds like a lot, but it was really not that bad. Removing the battery box and such gives extra room to maneuver, and I was/am quite happy we didn't have to further tear into the bike. I will be replacing my airbox this winter(with the airbox from this little tale) and I will be taking pictures and such at that time if there is any interest.

    Marko
     
    Marko, Jul 17, 2008
    #1
  2. Alive

    Alive Active Member

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    Be interesting to see if it works in reverse :)
     
    Alive, Jul 17, 2008
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  3. Marko

    Marko Member

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    Shouldn't have a problem going in reverse. Main issue would be pressure in the right direction without ripping your fingers up.
     
    Marko, Jul 17, 2008
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  4. wizard

    wizard Active Member

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    Re: NooBSchool: yanking an airbox without removing the engin

    i need to see the pictures, marco, as i believe it to be impossible. wiz.
     
    wizard, Jul 17, 2008
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  5. danno

    danno Member

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    Re: NooBSchool: yanking an airbox without removing the engin

    I witnessed this...it did in fact happen. And the airbox suffered no damage,save for a superficial scuff or two. Now,if I can only learn how to pee 91 octane,I'll be all set.
     
    danno, Jul 17, 2008
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  6. Marko

    Marko Member

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    Re: NooBSchool: yanking an airbox without removing the engin

    I will try and figure a way to get pictures up before I work on my bike this winter. Perhaps even some video if I can pilfer my ma's camera.

    And if you keep drinking that cheap beer Danno, in another ten years you might be :p
     
    Marko, Jul 18, 2008
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  7. kevineleven

    kevineleven Member

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    I can also attest--- I removed mine (albeit 3 years ago) with no damage and without removing the engine. I also run pods and open exhaust with stock jets and great performance, but noone believes that either, go figure.
     
    kevineleven, Jul 18, 2008
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  8. TIMEtoRIDE

    TIMEtoRIDE Active Member

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    So, was this in a 650 frame, or a 750 frame ???

    As I will be installing a box in my 750. And I don't like the idea of removing my intake manifolds, I'd rather scoot the engine forward an inch by removing all mounting brackets than mess with good boots.
     
    TIMEtoRIDE, Jul 18, 2008
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  9. Marko

    Marko Member

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    It was on a 650.
     
    Marko, Jul 18, 2008
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  10. biggmeany2000

    biggmeany2000 Member

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    Re: NooBSchool: yanking an airbox without removing the engin

    I also removed mine without damage. But also removed the starter.
     
    biggmeany2000, Jul 18, 2008
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