Air boxing not-very-clever.

[Blimp]

While checking to see if the engine oil was visible in the sight glass or was hiding in the sump, I noticed the air box was barely attached to the carb stubs. I've had hours of fun fitting that air box (standard) and can't understand why anyone would want to ditch them in favour of pods...I recalled that the last time I was out on the bike, it cut out while waiting at some traffic lights. Maybe that was why?
Anyway, I removed the tank and hardly needed to loosen the clamps in order to lift the 'box clear; as I suspected. I knew from bitter experience that re-fitting would be a pain, so I had already decided to split the 'box to make things a little easier. At least that's what I've found previously. On this occasion, however, it was not to be and I spent the next 40 minutes vainly struggling. The stubs the air box clamp to are very narrow, and the 'box keeps popping off as the clamp screws are tightened. I tried smearing a little red grease on the rubber to help it slide over the stubs, but of course that meant it slid off more easily, too. I tried heating the rubber with a hair dryer in case softening would help (the rubber is quite stiff in cooler temperatures), but that didn't work, either (the hair-dryer overheated and cut out). The problem is compounded by the fact that the carbs sit at a slight angle to the air box mounts, and wiggling the 'box is restricted a little by the way it fits at the front into a rubber grommet in a bracket on the frame. I considered sawing that bullet-shaped plastic protruberance off but baulked at butchering the 'box... Finally, though I was loath to do so, I pulled the rubber "trumpets" out of the box and attached them seperately to the carbs. This way I was able to get them fully on the the skinny carb stubs and fasten the clamp screw good and tight. I then lowered the lower section of the air box over the "trumpet" (or whatever they're called) and re-fitted the upper air box half. The reason I was reluctant to pull the...trumpets from the 'box is because when I acquired the bike they were not sealed to the box and rotated freely, which seemed wrong. I spent some time carefully applying mastic around the join to provide an air-tight seal.
I'll look forward to people implying I'm retarded because they "never have this problem", and in the unlikely event my endeavours actualy improve the bikes performance, I'll report back.
Blimp.

[HolerTogni]

Hi Blimp!

I'm glad you wrote this:

...
I'll look forward to people implying I'm retarded because they "never have this problem" ...
Blimp.

'Cause guess what - I was to write exactly this (without the "retarded" part, though).

Maybe you have these difficulties because your airbox housing is warped?

I honestly never had not such problems when (re-)fitting my airbox.

"Sliding fit" - greets from Munich!

[Blimp]

Hi, Holer. Thanks for replying. The only explanation I can think of, other than retardation, is that the rubber parts of the air box (what I refered to, for want of a better word, as "trumpets") are old and less flexable than they once were (aren't we all?). I would manage to get one side on the carb stub, but as I attempted to do the other carb the first one would slip off. This happened repeatedly. Seperating the trumpets ( I'm starting to regret using that term) from the air box allowed me to get them fully onto the carb stub. Once tightened they remained in place even as I juggled the air box back over them.
Regards,
Blimp

[HolerTogni]

Hi Blimp!

Don't worry about the correct term here (although I have to admit that I'm a huge fan of using the correct terms ).

According to the OEM parts catalogue (part 16, right?, they are just called "joint".

So I hope it's not illegal in your country to have some of these ...

Keeping the fire away from my "joints" - greets from Munich!

[dicky]

I must say up front that it is many years since I have removed and replaced the airbox, but when I did it was never a difficult task. From memory the hardest part was getting a long enough screwdriver to tighten the clamps. I recall fitting the rubbers to the carbs, then fully tightening them, then fitting the airbox into the rubbers and tightening them. Rinse, repeat, wipe hands on pants.
No lubricants needed except the mandatory neck oil used by all home mechanics.
Hard, perishing rubber is probably the cause of the problem, and we are all going to face it.
I'll see if I can find an alternative part.

[speedy]

Silicone spray is the thing when fitting rubber parts!
Speedy

[Blimp]

Well, thanks everyone for taking the trouble to respond.
I assumed (and we should never do that, I know) that since the air box comes off as a complete item, rubber "trumpets" (sorry, Holler) and all, that it should go back the same way. Doing it seperately is much easier, but raised the question (for me) of a potential air leak between item(s) 16 and the air box. Anyway, I took my license in my hands and threw caution to the winds during a ride around North Wales today and...everything seemed fine. No miss-fires, no stumbling or cutting out. So that's that, I suppose.

Places visited on trip into North Wales: First stop, Dobbshill on the A550 for petrol; the Old Stores bikers cafe, Pontblyddyn for tea; Betwys-y-coed for chips and more tea; Bala, same; LLangollen for petrol; Dobbshill, via Horseshoe Pass (no point stopping at the famous Ponderosa cafe because it is closed; indefinetly) for one last tea and a pee before home.