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Refitting standard airbox to an XJ900F

Discussion in 'XJ Technical Chat' started by XJ900F uk, May 20, 2017.

  1. XJ900F uk

    XJ900F uk New Member

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    This is reckoned by some to be impossible with an engine installed.
    Have read other threads where heat guns have been used to deform the box and then reform it after 'fitting'.
    That seemed a bit like 'cheating' ?

    Needed to change the one on my partly-stripped 'project' bike as one of the moulded-in sidepanel inserts was seized on the screw and turning - plus the PO had done some more damage trying to remove said screw.
    [Noticed ... a PO had cut off the rearmost top 'square' boss with threaded fitment ......]

    Had/already removed :- exhaust system, rubbers on box, inlet stubs and carbs, starter motor, alternator cover, choke cable bracket, battery holder. Tilted engine forward.
    Old box came out (on left side) very easily.
    New, complete, box would NOT go back in. No way.
    So ... worked out standard top boss was in the way - but - could easily be put back to act as both spacer and fixing point.
    Hacksawed it of off about 1/8" above box - AFTER using it to guide a pilot drill down through the top of airbox. Then drilled out this hole to be 6mm clearance.
    Refitted box from l/h side - no heatgun needed but still tight.
    Screwed approx 30mm x 6mm stainless button-head down through lug on frame and pulled up the 'loose' boss.
    Put a penny washer on box top to take place of saw cut thickness and then wiggled box upwards over thread and fitted 16mm o/d washer [fits between internal ribs] and 6mm nyloc to hold it all in place.
    There being room over the original filter to allow the bolt/nut to 'intrude' through into the box.
    So .... virtually invisible, no heatgun efforts, no burnt fingers, very secure - especially with two front bolts untouched.
     
    Stumplifter likes this.
  2. Stumplifter

    Stumplifter Well-Known Member

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    Nice!
    Any pics?
     
  3. XJ900F uk

    XJ900F uk New Member

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    Ah. I did this at a fair speed because jet black thundercloud/rain were approaching.
    I will try and take pics now it is on the bike - best I can do.

    Sorry about typo in first post "of off" should just be "off".
     
  4. XJ900F uk

    XJ900F uk New Member

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