SuzukiSavage.com - Removing the Air Box

Tiefighterpilot

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Removing the Air Box
05/25/10 at 21:32:39

I just got my cone air filter. I was looking to install that so I was looking at removing the Air Box to make room for the cone filter, instead of putting it directly on the carb.

I was looking at the Clymer service manual and I had couple of question on removing the Air Box.

1. Can the Air Box be removed without taking out the Battery Box?
2. If so, where is the mounting screw for the Battery Box? Inside the Box?
3. Does the Carb have to be removed?
4. Anything else need to come off before the Battery Box can be removed?

Thanks in advance.

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2007 S40, KN Cone Air Filter, BCB Pipe, BCB Fender and seat, Superbrace Fork Brace with guard, 55 Pilot, 155 Main, washer mod, iridium spark plug, no afterfire, some engine breaking noise

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onelunger YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 38	Re: Removing the Air Box Reply #1 - 05/26/10 at 04:34:38 Battery box is a piece of cake. There are 4 bolts in the bottom of it (inside). Pull out the battery, remove the bolts and it slides right out. Never removed the airbox but I imagine that it would be easier w/ the battery box out of the way.
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BurnPgh Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1732	Re: Removing the Air Box Reply #2 - 05/26/10 at 05:22:30 Its pretty near impossible without removing the battery box and even then it was always a PITA for me. Theres two bolts on either side of the airbox near the top and on tucked hidden by the bottom on the left of the airbox (left assuming you're sitting on the bike). Then wiggle, tug, and pull forward while grumbling.
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spacepirates

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Igni Ferroque

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Re: Removing the Air Box
Reply #3 - 05/26/10 at 05:39:27

BurnPgh wrote on 05/26/10 at 05:22:30:

Its pretty near impossible without removing the battery box and even then it was always a PITA for me. Theres two bolts on either side of the airbox near the top and on tucked hidden by the bottom on the left of the airbox (left assuming you're sitting on the bike). Then wiggle, tug, and pull forward while grumbling.

Second on the PITA. I removed my battery box, but not the carb when i removed my air box. would have been easier with out the carb in there. that air box is BIG. You'll most likely have to rejet anyways, so you might as well pull the carb.

Don't forgot about the CDi that mounts to the left side of the air box. you'll have to put that elsewhere. I lost my chrome tool cover a long time ago, so i zip tied/taped the CDi there, fits real nice.

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Tiefighterpilot Senior Member Offline Daily Rider Posts: 346 San Francisco	Re: Removing the Air Box Reply #4 - 05/26/10 at 19:44:48 Thanks everyone. I have really tried to avoid taking the carb off the bike because of all the hoses (what a mess) and direction on clymers not being so clear (well at least to me). But it looks like I will be taking the carb and tank off. I might as well clean it. I tried.
Back to top	2007 S40, KN Cone Air Filter, BCB Pipe, BCB Fender and seat, Superbrace Fork Brace with guard, 55 Pilot, 155 Main, washer mod, iridium spark plug, no afterfire, some engine breaking noise IP Logged

jabman Senior Member Offline Posts: 411 England Gender:	Re: Removing the Air Box Reply #5 - 05/26/10 at 23:37:09 it will be worth it
Back to top	93" savage, 177.5 main, 52.5 w/holes 3 turns out , middle circlip, 6" k&n round filter, Dyna muffler, TKAT brace IP Logged

Tiefighterpilot Senior Member Offline Daily Rider Posts: 346 San Francisco	Re: Removing the Air Box Reply #6 - 06/05/10 at 22:38:07 One more thing... what do I do with the breather hose attached to the Airbox? Thanks in advance.
Back to top	2007 S40, KN Cone Air Filter, BCB Pipe, BCB Fender and seat, Superbrace Fork Brace with guard, 55 Pilot, 155 Main, washer mod, iridium spark plug, no afterfire, some engine breaking noise IP Logged

BurnPgh

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Re: Removing the Air Box
Reply #7 - 06/05/10 at 22:51:15

put a little cone filter on the end of the hose and place it along the frame, preferably above the breather port. I got mine from Pepboys. I had to cut a section of a ball point pen tube to insert into the hose and the filter and put a clamp on both. If I had a camera and knew how to use it Id post a pic, but if you go into pepboys or advanced auto you ought to find a little cone filter and be able to figure it out. I paid $6.

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Tiefighterpilot Senior Member Offline Daily Rider Posts: 346 San Francisco	Re: Removing the Air Box Reply #8 - 06/05/10 at 22:55:25 small (air) cone filter? Like this one? http://www.knfilters.com/search/product.aspx?Prod=RU-5162
Back to top	2007 S40, KN Cone Air Filter, BCB Pipe, BCB Fender and seat, Superbrace Fork Brace with guard, 55 Pilot, 155 Main, washer mod, iridium spark plug, no afterfire, some engine breaking noise IP Logged

BurnPgh Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1732	Re: Removing the Air Box Reply #9 - 06/05/10 at 22:57:08 yup
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Tiefighterpilot Senior Member Offline Daily Rider Posts: 346 San Francisco	Re: Removing the Air Box Reply #10 - 06/05/10 at 22:59:49 Cool thanks.
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