1. Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

Airbox re-installation

Discussion in 'XJ Technical Chat' started by cds1984, Jul 24, 2016.

  1. cds1984

    cds1984 Active Member

    Messages:
    907
    Likes Received:
    195
    Trophy Points:
    43
    Location:
    Perth, Western Australia
    Okay...
    Thought I'd mention this since I.... kinda buggered it up.
    I have had pod filters on my 750 since I put a 818 kit through it but found that they basically really sucked when I washed the bike.
    They weren't paper pods but uni-filter pods from australia made of foam with an oil/fuel mix when installing them originally.
    At any rate, they did the job but whenever I hit the bike with the pressure cleaner I ended up squeezing out the pods so i decided to put the airbox back in without removing the motor and this is my story :)

    Had to be possible... I thought...
    First I removed everything that would get in the way.
    With battery box and all the carb boots on the head off I thought "surely those guys who designed this would have thought of this scenario!"
    I remembered a thread with some chap with a heatgun but thought... no surely not!
    So...
    I worked out how to put it in.
    First you slip it in sideways and force the hell out of it and bend it and bash it and eventually when it is cracked and back in place...
    You get a few cable ties and a soldering iron and weld all the cracks up.
    Thank you for reading!

    PS: (it was only one crack really)

    Damn pods... another reason not to use them!
     
    cds1984, Jul 24, 2016
    #1
    rocs82650, Stumplifter, Jetfixer and 1 other person like this.
  2. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

    Messages:
    8,885
    Likes Received:
    1,802
    Trophy Points:
    113
    Location:
    The room where it happened
    Post of the Year!!
     
    chacal, Jul 24, 2016
    #2
    Yardawg, Jetfixer and Lightcs1776 like this.
  3. tabaka45

    tabaka45 Well-Known Member

    Messages:
    2,359
    Likes Received:
    500
    Trophy Points:
    113
    Location:
    Brunswick, Georgia
    Good for you! I thought you had to remove the engine to get the air box in.
     
    tabaka45, Jul 24, 2016
    #3
    Jetfixer likes this.
  4. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,613
    Likes Received:
    6,707
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    Removing the carbs and starer makes for a lot more room. Pulling the battery box helps too.
     
    k-moe, Jul 24, 2016
    #4
  5. Stumplifter

    Stumplifter Well-Known Member

    Messages:
    2,792
    Likes Received:
    1,051
    Trophy Points:
    113
    Location:
    near Irma, WI
    Somebody sticky this! :)

    Brilliant.
     
    Stumplifter, Jul 24, 2016
    #5
  6. Kevin A

    Kevin A Member

    Messages:
    38
    Likes Received:
    12
    Trophy Points:
    8
    Location:
    hamilton ontario canada
    so it is possible to get the air box back in without taking the motor out ? I hope so . lol
     
    Kevin A, Jul 24, 2016
    #6
  7. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,613
    Likes Received:
    6,707
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    Yes.

    There's about a gazillion threads about that.
    Here's one with a video.
    http://xjbikes.com/forums/threads/82-xj750-air-box-installation.56434/

    Note: Carbs off, starter out, battery box out.

    He also has the intake boots off. I would recommend against removing yours unless you plan on replacing them anyway. If you do remove give a good soak with penetration oil and plan on having a few screws snap off. I think you can manage to get the airbox in without removing the boots if you remove the R/R and TCI mounting panel to give you more room to manouver the air box.
     
    k-moe, Jul 24, 2016
    #7

Share This Page