I cant get my factory air cleaner box back on. Please help?

[Suckerpunch]

Today I pulled the air box and carbs to replace the four cracked boots that go on to the motor side. I have put back on the carbs but, I cant figure how to get tha factory air box back on. Ive tried every angle possible. I must be missing something and cant figure it out!!!

[DGXSER]

Well, typically the top part of the air box has to go back on BEFORE the carbs go in. Its a big reason alot of folks ditch the air box and go to pod filters.

To install it, that snorkel has to go up and back in the frame area above the battery box. Now, Bikerphil and perhaps others have posted that they cut the snorkel back to about 2" or so to let it go in with the carbs in place, making carb removal and install MUCH easier.

[XSokieSPECIAL]

Heh heh heh........ya gotta put the box in th bike first and tie it back and wrestle the carbs in between it and the carb boots.

You'll learn the right words to get it done.

[Suckerpunch]

DAMN!!!! oh well I now have something to do tomorrow

When messing with the carbs today I had them in every position possible. top, bottom, side to side, upside down and so on. I did not hit any of the adjustments, will I need to have a shop re-tune them?

I did haver a problem with the first carb on the left side. Once I put fuel from the tank it started to over flow. I gave it a couple small taps with a rubber mallet to help set the float. It worked but, should I be concerned about that messing up the carb too?

[bikerphil]

It\'s ok to turn them upside down, there is no check ball inside like some automotive carbs have.

[81xsproject]

This is why some risk performance for pods

[Toolmaker Tim]

Airbox Contortions

Definitely chop the snorkle back, makes life much easier. I also took my Dermel and cut the middle of the airbox top bracket out. DON'T DISASSEMBLE OR TAKE THE SCREWS OUT. Just cut the section that has the screw hole in the middle top out. The two tabs on the back of the airbox that have screws going through them are plenty of support. That bleeping middle hanger is useless and a PITA. It just gets in the way. After you do that you can put the airbox in easily one half at a time.

[motoman]

After you remove the carbs install the filter housing WITHOUT the lower section on. Leave it unbolted and lower front of air box as far down as it will go. Install carb rack, raise filter housing back up and onto back of carbs. Same for future removal of carbs, remove lower portion of filter housing and PVC hose, let lower portion of housing rest lowered in front.

[vileneeds]

I just install the carbs completely and the lube all the boots and the carb. it took twenty minutes to do from start to finish. I was swearing a lot and bled a little but a liberal ammount of lube and he boots will be easy to persuade.

[psycoreefer]

After you remove the carbs install the filter housing WITHOUT the lower section on. Leave it unbolted and lower front of air box as far down as it will go. Install carb rack, raise filter housing back up and onto back of carbs. Same for future removal of carbs, remove lower portion of filter housing and PVC hose, let lower portion of housing rest lowered in front.

+1 on this, what I do
The first time...
1. Wrestle the carbs out and remove the above(in a different post) mentioned top brace. I do take the screws out and remove it, but be care full because if the spacers and stuff inside fall out its PITA to put back together, maybe safer to cut it, or bend it, but I like to be able to go back to stock if I ever choose to. I do not cut the snorkle, not needed.

Every time after...
1. Remove the bottom of the air box
2. Loosen all the carb boot clamps, remove the two side screws from the air box, unhook any hoses and cables that are in the way.
3. Pull the top of the air box backwards off the carbs, then push it down so it is resting below the carbs.
4. Pull the carbs back off the engine side boots, then pull them out from the left, you can do the right, but I always seem to be standing on the left side of the bike at this point.
5. Service your carbs....
Installation is the reverse of removal.

I'd be willing to bet I can remove my carbs nearly as fast as anyone with pods, removal or installation takes me 10 minutes, maybe 15 if I have to look for tools.

[Suckerpunch]

+1 on this, what I do
The first time...
1. Wrestle the carbs out and remove the above(in a different post) mentioned top brace. I do take the screws out and remove it, but be care full because if the spacers and stuff inside fall out its PITA to put back together, maybe safer to cut it, or bend it, but I like to be able to go back to stock if I ever choose to. I do not cut the snorkle, not needed.

Every time after...
1. Remove the bottom of the air box
2. Loosen all the carb boot clamps, remove the two side screws from the air box, unhook any hoses and cables that are in the way.
3. Pull the top of the air box backwards off the carbs, then push it down so it is resting below the carbs.
4. Pull the carbs back off the engine side boots, then pull them out from the left, you can do the right, but I always seem to be standing on the left side of the bike at this point.
5. Service your carbs....
Installation is the reverse of removal.

I'd be willing to bet I can remove my carbs nearly as fast as anyone with pods, removal or installation takes me 10 minutes, maybe 15 if I have to look for tools.

Good, Im moving to Carson in about three weeks so, If I cant get it. your hired

[psycoreefer]

cool, it'll be nice to have another xs'er nearby. My garage is always open, well it is when I'm home anyways.

[Suckerpunch]

Done! did it with out cutting or bending anything. What a PITA though

[petejw]

hey psycoreefer,
i can remove my carbs in less than 2 min with pods,
dont need to remove seat or tank, just the fuel lines,
4 clamps and the vac adv hose.

[DiverRay]

petejw said:

hey psycoreefer,
i can remove my carbs in less than 2 min with pods,
dont need to remove seat or tank, just the fuel lines,
4 clamps and the vac adv hose.

Yeah Pete, that's because everything is upside down where you live!
Pods do help, but once you get the order down, even stock isn't THAT bad!