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Message started by il67bp on 11/11/08 at 13:12:51

Title: removing airbox
Post by il67bp on 11/11/08 at 13:12:51

what do i need to do t remove the airbox ? i cant seem to figure it out

Title: Re: removing airbox
Post by eanon on 11/11/08 at 13:19:21

Make sure you get all the bolts. There's one hidden on the bottom, towards the rear wheel, if I remember correctly. Gotta get down on the floor to see it. Then you still might have to do some twisting and pulling. I did. Watch out for wires!

Title: Re: removing airbox
Post by il67bp on 11/11/08 at 13:21:48

does the battery have to be removed?

Title: Re: removing airbox
Post by Demin on 11/11/08 at 13:32:34

Yes,the airbox has to go forward to be removed.Here is the bolt that everybody misses.Just above the belt.
http://w3.bikepics.com/pics/2008/06/27/bikepics-1334785-800.jpg

Title: Re: removing airbox
Post by eanon on 11/11/08 at 13:32:42

I took out the battery and the battery box. Gives you a lot more room to move around.

Title: Re: removing airbox
Post by il67bp on 11/11/08 at 13:42:23

thanks alot guys im going to attept this now

Title: Re: removing airbox
Post by mick on 11/11/08 at 19:21:23

65603A3B6E7C0C0 wrote:

what do i need to do t remove the airbox ? i cant seem to figure it out

Are you going to put in a K & N cone air filter?
if you are can you give me the info on the part number,I would like to do that mod to my bike,makes for easier access to the carb.

Title: Re: removing airbox
Post by Jimmer on 11/12/08 at 04:59:21

I installed a K&N filter. Number was R-1260Hope this helps

Title: Re: removing airbox
Post by skrapiron -FSO on 11/12/08 at 05:16:38

When you install the K&N cone, you really need to move the battery box back to where the air-box used to sit. Otherwise, the clearance for the filter is not quite there and you have to squish it on top of the battery box.

You can remove the battery box lid, but doing so, you will lose the ability to mount chrome trim that houses the spare fuse and tool bag.

Once the box is moved back, the carb can be removed without taking off the seat and tank. It sounds better with the open air-filter element as well.

Title: Re: removing airbox
Post by Savage_Amusement on 11/12/08 at 12:14:14

I was able to lean my battery box back a little in its stock pos without much trouble and the filter fit a lot better that way. I'd like to move it all the way back, but something would have to be fabbed.

Title: Re: removing airbox
Post by il67bp on 11/12/08 at 16:56:26

now heres my next question. how do you get that battery box out?

Title: Re: removing airbox
Post by Demin on 11/12/08 at 17:06:32

Pull the battery out of the box.There are 4 bolts through the bottom of the box.

Title: Re: removing airbox
Post by diamond jim on 02/04/09 at 16:27:22

I removed the airbox today and moved the battery box back. Here's what I did: I made two simple brackets (don't know if flat pieces qualify as brackets). They are 1' wide x maybe 3/16" thick steel. I drilled 3 holes in each. The brackets extend the base where the battery box mounts.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/batteryboxmount.jpg
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021319-1.jpg

The mod moved the battery box back about 1.5". This is as far as you can move the battery box without either doing some serious modding to the battery box or ditching the battery box altogether and coming up with a custom retainer. With this mod the only thing I had to do on the box itself is shape the lower right rear corner of the box. The corner of the tab where the tool box cover lock is mounted with 2 phillips screws bumped into the curvature of the frame. Some very minor reshaping of the tab with a hand file fixed it.

Here you can see the extra space that it provides.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/comparison.jpg

Title: Re: removing airbox
Post by SavRon on 02/04/09 at 17:27:27

I too was intending on installing a cone filter this spring.

Was wondering if you could just move the battery box back and only use 2 of the bolts to keep it mounted, and if this would give enough clearance for the filter ? Would a bracket be needed like Diamond Jim posted ?

Title: Re: removing airbox
Post by diamond jim on 02/04/09 at 18:29:47

Just using 2 of the screws wouldn't be strong enough. It's pretty easy to make the brackets, though. I used only a drill, hacksaw and a file. No major power tools. I also used one of these brackets.
http://www.fdsons.com/images/national/corner_brace_n220-178.jpg

The one I used is thicker than the one in the pic but I couldn't find and exact pic. I cut off each side and used one of the holes in each piece for the front bolts. The other two holes on each bracket had to be drilled because of the spacing.

Take one of the 6mm bolts with you to a hardware store. Get 2 6mm bolts that are a little shorter than the stock ones and get 2 6mm bolts that are a little longer than the stock bolts. Get 4 nuts and 8 washers for the 4 new bolts.

Use the 2 shorter bolts, 2 nuts and 4 washers (top and bottom for each bolt) up front.

Use the 2 longer bolts with washers (top) in the middle. These will screw into the rear set of frame threads.

Use 2 stock bolts with the other 2 nuts and washers (bottom) for the rear.

This may not make sense reading it but when you take it apart and fab the brackets it'll make sense.

Title: Re: removing airbox
Post by SimonTuffGuy on 02/05/09 at 06:10:52

Jim - You make so much sense with the pictures and diagrams you provide. You're a true asset to this forum. :)

Another one of my "too many to list" mods that I need to get working on.

Title: Re: removing airbox
Post by diamond jim on 02/05/09 at 07:16:37

Thanks. I love finding easy, low cost ways to improve my bikes.

Title: Re: removing airbox
Post by Savage_Amusement on 02/05/09 at 13:23:05

I will be moving that battery box back soon, thanks for filling in that gap for me too lol.

Title: Re: removing airbox
Post by diamond jim on 02/05/09 at 18:02:07

I finished my airbox removal/battery moved back project. For bonus, I ran the wires between the frame supports for the rear fender to give it a cleaner look. I had to lengthen about six wires total, including making a new, longer ground wire that goes from the battery negative to the bolt on the engine by the clutch.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021325.jpg

I made an aluminum cross brace to go across the frame, underneath the seat. The computer box is mounted to the brace.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/airboxremoval-1.jpg

To me, having the airbox removed and moving the battery back gives the illusion that the bike is longer.

Title: Re: removing airbox
Post by Savage_Amusement on 02/06/09 at 07:36:50

I don't miss my air box at all. I love the more open look. I agree it makes it look longer and a lot different.

Title: Re: removing airbox
Post by SimonTuffGuy on 02/06/09 at 08:56:31

Looks great without that stuff. I'm going to be doing this as soon as my garage is warm enough. :)

Title: Re: removing airbox
Post by SimonTuffGuy on 02/06/09 at 17:16:26

Well... I tackled the airbox removal mod this evening... :) Let me just say, a HUGE PITA!

There is certainly not enough space in the frame to remove that. I was able to remove it though with the belt cover in place, simply slipped my 10mm socket under the belt guard enough to break it free, then was able to spin it by hand.

The box was getting stuck on the carb "lip"... But, with a little bit of blunt force it popped straight out.

Anyways... I pulled the box, but that's about it. I'll have to sort out re-installing it sometime this weekend.

Title: Re: removing airbox
Post by diamond jim on 02/06/09 at 18:33:04

Ha! It didn't take long for your garage to warm up!

Title: Re: removing airbox
Post by SimonTuffGuy on 02/06/09 at 18:41:35

It wasn't warm. :-P I just got the itch to do some mods and when I started taking the seat off, I couldn't stop!

I'm hoping to get some more done tomorrow or Sunday. :)

Title: Re: removing airbox
Post by Rogue_Cheddar on 02/06/09 at 19:35:29

6C565250516B4A5959784A463F0 wrote:

It wasn't warm. :-P I just got the itch to do some mods and when I started taking the seat off, I couldn't stop!

I'm hoping to get some more done tomorrow or Sunday. :)

I couldn't stop either. Taking stuff apart is FUNdamental! :D
Getting it all sorted and put back together? :-/

Title: Re: removing airbox
Post by SimonTuffGuy on 02/07/09 at 18:46:10

I got the brackets, nuts and bolts that I needed this afternoon. Got tied up in my Festiva project though half way through though.

The weather was beautiful today though, it would've been great to go for a cruise.

I'm thinking of finding a different type of battery box. If I went with something smaller, it could fit even further back in the frame. I don't really use the storage space anyways.

Title: Re: removing airbox
Post by SimonTuffGuy on 02/08/09 at 18:02:29

Welp...Attempted a bit today. Got my brackets cut and drilled like I needed. But I'll need to extend my negative battery cable and another wire before I can remount the battery box. I'll run them up along the frame for a cleaner look (as Jim mentioned).

One question... What did you do with the tabs that were leftover from the air box? There's one on each side. Did you leave them go or cut them off?

Title: Re: removing airbox
Post by diamond jim on 02/08/09 at 18:29:15

I cut them off.

You'll need 8 gauge wire for the negative wire and new connectors for both ends. I tried removing the connectors on the stock wire to reuse but had no luck. I got the black 8 gauge wire at Lowes for 61 cents per foot. I got the connectors at Autozone.

I also extended:
- the short black/white stripe 18 gauge wire that also goes to the negative post and has a connector.
- the blue 18 gauge wire that goes up and ends with a connector on the left side of the frame under the tank.
- the green and orange wires that split off from part of the wiring harness somewhere around the top of the battery area and ends with a connector.

Umm... I think that's it. I don't think I'm forgetting any but if I have you'll discover it.

Title: Re: removing airbox
Post by SimonTuffGuy on 02/08/09 at 18:46:02

Thanks. I moved some of the wires around a bit. Looks like I should only have to extend the negative cable ... I was thinking of extending the part that attaches to the bike vs. the battery, I'd only have to extend that 1 wire at that point. And the blue wire that runs under the tank. I untangled the rest of the wires... Everything that was running up the side seemed to be twisted together, after untwisting all of them, it seems that most of the wires are long enough as they are (and some could probably be cut down to size, especially if I'm moving the rectifier around and stuff too).

I need more daylight to work on it. The bottom portion of our garage has sucky lights and it's a big pain to do anything with. Plus, it's filled with junk, so I've got about 1.5' on each side of the bike to work and that's just not enough.

I probably will cut those tabs off though. I need to get myself a good cutoff wheel. I guess I'll have to break out the Dremmel. Thanks!

Title: Re: removing airbox
Post by Savage_Amusement on 02/09/09 at 04:53:05

I noticed when I was doing mine that there are a lot of wires that are a lot longer than they seem. I undid a lot of the bundles and found tons of extra lengths. Whom ever wired my bike made no sense to me. A few wires would run up one bundle and half way down another and back up.

Title: Re: removing airbox
Post by SimonTuffGuy on 02/09/09 at 05:08:43

I noticed that as well! I'm figuring I'll do something similar instead of cutting the wires down to length and splicing them back together... That way if I ever need to move something again, I'll have the length of wire I need right away.

Title: Re: removing airbox
Post by SimonTuffGuy on 02/23/09 at 05:36:51

Tried my luck at this again this weekend... This time, new steel to mess with (without holes first, as that seemed to be my initial problem) and a little more patience.

I guess it paid off... I got the brackets cut, drilled, and mounted. The one on the left side (while sitting on the bike) seems to be touching the frame though and there is no way to get a bolt in through it unless you'd raise the box. However, it seems that the bolts that I've got in now would hold it in place just fine.

My only problem at this point is... the filter STILL won't fit! I bought one of those from the site here. Maybe if I would've put the filter on first, and then put the battery box/battery in afterwards it would've fit right... But if I have to maintenance anything there... A huge pain?

I'm thinking of doing what I was thinking of before... And just going the route of a custom box of some sort.

Title: Re: removing airbox
Post by diamond jim on 02/23/09 at 06:13:05

The back edge of the left bracket (left being sitting on the bike and looking down) will touch the frame if it's the same dimensions as the right one. I remember doing two things to remedy this- 1) I ground maybe 1/16" off the back of the left bracket (not too much), and 2) angled and rounded off the bottom edge of the back of the bracket until I got clearance.