airbox removal

New to the site and new to XJ ownership. So, hi to everyone. Question: Is it possible to remove the airbox without idk, cutting the frame?

 

From what I've been told, you have to pull the engine to get the air box out.

 

either that or just cut the airbox in half.

 

Seriously, that's the only way I can see to do it.

 

You take the Engine off the Mounts and tilt it until you have room to slide the Airbox out of there ... or, ... you take the airbox out in chunks.

Keep in mind.

Once you damage the airbox there's no going back. I'd rather see you preserve the Airbox and set it aside (for future reference) than have nothing to go back to if your adventure in tuning with Pod Filters proves to be a technical nightmare. It can happen.

It's much easier to put a bike on the razors edge of fine tuning with the stock set-up. Pods require re-Jetting. Maybe a Kit. And, its not always the best situation to try and do all the re-Jetting and get the Maximum Performance out of the Bike.

Open for debate is the difference you obtain using Pod Filters rather than just tuning the bike to the Maximum Performance obtainable Stock.

 

It IS possible, to get it out, but you'll have to really bend, push, force, etc... I removed ONE that way, and installed ONE that way. I don't recommend it. It probably would have been quicker to remove the engine under normal circumstances. However, in this case ,the frame had been tweaked just enough to make engine removal impossible.( I did remove the engine at another time, but that was involved cutting the frame and throwing the frame away.

 

i find it unbelieveable that no one has made a chart of pod/jet sizes. I mean, they are all the same motors with the same carbs so why not save a bunch of people a bunch of money and fumbling around. All you would have to do is say what filters you used and what jets you are using and how many turns on the air screws. SIMPLE...watch I'll start one.

 

it is possible to remove box without moving engine... you might get it out without breaking it but thats if you go very gentle while doing it.. i had mine out very quickly but still managed to crack it, only about 3 inches long not to bad.. havent put it back in yet due to waiting on parts for the starter clutch...

 

it is possible to remove box without moving engine... you might get it out without breaking it but thats if you go very gentle while doing it.. i had mine out very quickly but still managed to crack it, only about 3 inches long not to bad.. havent put it back in yet due to waiting on parts for the starter clutch...

 

I just did this twice within the last month, WITHOUT cutting or otherwise damaging the airbox, or pulling the engine/starter/etcetera. I'm pulling my carbs again as soon as it starts raining(forgot to bench synch them) and I will take some photots and video if I can of how to remove/replace the airbox.

 

I was able to get mine in (the original one was broken) from the right side of the bike. It was an ordeal and I remember being shocked when I got it in without breaking but it is possible. I just pulled the carbs and boots off.

 

It is amazing what the engineers were thinking of when they made parts of the bike so hard to work on. Some modern bikes are even worse.

 

Look at the bright side.
Some of us are riding 25-year-old bikes that look as good and run better than the day some salesman handed-over the paperwork and keys to the original owners.

Although they are getting real old; they're still on-the-road and going strong!
We've banded together and manage to help one-another out.
It's too bad that we aren't officially keeping score. I'd like to know how many we have PUT back on-the-road!

Having one of these bikes that YOU repaired. That YOU restored. That YOU customized and tuned-up. That YOU have the keys too and can go-out and get-on, start-up and ride around the block or ride 'til you pull-in for gas, fill-up and keep riding watching the odometer click to a higher number, mile after mile all day long is a magical way of life that we take for granted and those not like us cannot begin to understand.

We own it!
We ride it.
We turn envious heads as we ride by.
There's a lot of ways to enjoy a warm, sunny day.
But, nones better than be out riding your bike.

 

There was a post on 17th July by Marco, called "NooBSchool yanking an airbox without removing the engine" I requested pictorial proof of this event, but so far it has not been forthcoming. Wiz.

 

"There was a post on 17th July by Marco, called "NooBSchool yanking an airbox without removing the engine" I requested pictorial proof of this event, but so far it has not been forthcoming. Wiz."

Guilty as charged. Excuse forthcoming...
The whether here has been shit(Rain, hail, etc.)

However! It's been clear for about 15 minutes. If it holds a couple more, I'm on my way outside to do this.

 

I got the airbox out of my XJ650 Maxim by taking off the carbs AND the manifold boots then squeezing, pushing, pulling etc - and the damn airbox still cracked a tiny bit along the righthand wall. Got it out in one piece, though - more or less...

 

Alright, as promised, here's the pics. Only posted taking it out. To put it back in, go in reverse. I did take video, but it came out horribly, so pics only for now. As a note, if your airbox is wicked brittle due to age, it is likely to crack. Also, a couple of these are out of order I think, but it gives you a good idea.

For these, remove the box lid, undo and flop out the electrical component panel, the battery box, and the clutch-cable bracket, and remove the carbs and boots.






Then just wiggle n pull. You'll know when you got it. Don't force it. Make sure to utilize the extra space created by flopping the panel out and liberating the battery box. WATCH YOUR WIRING!

























And drum-roll please...






Viola.

 

What a great description. Should be engraved in stone somewhere. I bought my 81 XJ650 Maxim 5 years ago as a basketcase and I had no idea how to repair a bike. With the friendly and patient help of Rick'O'Matic and many other members of this forum and the mica-peak xj owners email forum, I managed to pretty much rebuild ol' "Blackie" from the ground up.
That's why I've had no reservations about using it as a daily vehicle all this summer. Our beat up old Mazda has needed work and having just bought a house, my wife and I have been short of cash to fix the car. So the Maxim has been filling in admirably. For commuting to work, blasting around in the evenings, going on two-up trips out of town on the weekend - even the odd shopping trip (with a backpack). Sure, I bring along some tools when I'm on the road - and a tire plug kit - but I'd do that with any bike.
When you've got them running right, these bikes are pretty much bulletproof and a real pleasure to ride.

 

Some people would rather lick hot asphalt than remove intake boots.
The other way- - unbolt and slide the engine forward and down- - do you have to remove the exhaust from the head, or can everything just hang?

 

TimetoRide,
I don't much mind removing them, but for some it might be a hassle. I would think doing the whole engine or the starter and whatnot would be more of a hassle. For reattaching the carbs/intake boots, I simply attach the two middle intake boots, and the end ones(but only on one bolt.) then I put the carbs into the two central ones, and slide the end ones up and on. Then tighten the clamps and insert the remaining bolts.

 

Yeah, I've heard the warnings about snapping the bolts securing the intake manifold boots like old breadsticks. Luckily, I didn't have that problem and I've used copper grease on them to make sure it DOESN'T happen in the future.

 

Marko I can't believe you did this in bare feet! You animal! Thanks for taking the time to do this!

 

Another photograph to be placed in evidence to add strength to what some call a myth.

But, there it is ... a motorcycle engine with the legendary BigFoot in the background!

 

Dig on those ammo-can saddlebags!

 

The original question pertained to an XJ 550 Seca. Which, after careful and thoughtful review: The airbox either has to be cut or the engine unbolted and moved forward or removed completely.

 

I got mine out with only one small broken piece. You just have to swear A LOT...that is key. And maybe a couple of beers.

 

I've found it most easy to remove the airbox with the help of a carefully used heat gun. I evenly heat the sides and bottom of the filter area, and when the plastic can give, I "fold it" towards the front of the box. Easy out........once out, straighten the plastic before it cools. I do the same to put it back in. No breaks.

fwiw,

dave

 

I sit here in awe Marko, it seems you have performed the impossible (and I did try many times myself)! Thank you for your photos and efforts.

 

im just wondering on a theory..... im rebuilding my 82 that the previous owner disassembled.... i was contimplating taking off the back tire.... the air box and all the guts are disconnected right now... anyone think i might be able to get it from the rear? has anyone tried it? if not... i suppose id give it a go.

 

Amen to that!

 

game over... well done Marko

 

lol..... to no avail on an answer to my question... i have one. lol. I got my airbox back in on my xj650 from the rear. took off tire, and slid it in... passenger side first... only problems i had was getting the "drivers side" past the last piece of frame... i CAREFULLY took a rubber mallot and gave it two or three "baby" swings and it went in.... no swearing, no cutting, and no bs.... hopw it helps to anyone... i was going to take pictures but i was working in the rain

 

All this is just fine for the bike pictured, BUT NOT FOR A 1982 750 MAXIM!!! There must be subtle differences in the frames/ engines.