Air boxing not-very-clever.
Posted: Sun Mar 23, 2025 9:57 pm
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.
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.
).