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Airbox removal and re-installation
Airbox removal and re-installation.
I struggled with this yesterday and after sleeping on it, I knocked it out pretty quickly this morning.
To help others, this is what I did and would do differently.
Removal is pretty easy, though tedious. Loosen the clamp on the carb hose and use an 8mm wrench to slowly remove the 5 lock nuts connecting the air boot to the filter frame. The whole thing is fairly flexible and comes out with a little force.
Re-install(headlamp is a must):
1. Remove the seat, battery and tray, and air filter. This is a must as it will allow you to push the inner filter frame back into the outer boot part. This was the key for me, I don’t see how it would be possible any other way but if I am wrong let me know.
2. I first pushed the boot in place and connected to the carb first. I applied a tiny bit of dishwashing liquid to the inside of the hose and it slipped right on.
3. Finally start working each bolt through the five holes. This was a pain but it helped to use a flat head screw driver to push and get things aligned. At one point I used a pair of needle nose pliers to grab the rubber edge of the boot and stretch it so that it would align with the holes.
4. I added the lock nuts to each bolt as I got them pushed through. Four were pretty easy but the upper left is a bitch because it is cramped out by the gas cylinder attached to the rear shock. I managed to get it on by holding the nut in a pair of needle nose pliers and playing operation for about 15 minutes.
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