Need Help - Tell me the airbox secret

[mcmotohistory]

WTF I don't get it. If the carbs are on I cant get the airbox in place. If I take off the carbs I can install the airbox but then I can't get the carbs back in place? Whats the secret?? :confused

[BA80]

Take the 3 mounting bolts out of the airbox mounting brackets. Pry the upper mount (by the tank mount) forward with a screwdriver until you can get it under the tab on the frame that it bolts to. (It's flexible enough)

Push the airbox down and back as far as possible. The rubber boots on the airbox will drop just below the carbs and you can pull the carbs straight back and out.

Reverse procedure to reinstall

[crazy steve]

Video.... http://www.xs11.com/forum/showthread.php?t=35349

[fredintoon]

WTF I don't get it. If the carbs are on I cant get the airbox in place. If I take off the carbs I can install the airbox but then I can't get the carbs back in place? Whats the secret?? :confused

Hi mcmotohistory,
while some claim the airbox/carb install is easy and they've got a video to prove it, my personal history is different.
It started with the three Bs:- Blood, bandaids and blasphemy.
went from there to replacing the stock airbox with four UniPods.
In accordance with Finagle's law of Dynamic Negatives, while I was fighting with the stock airbox and taking some hours just to access my carbs I had to clean the bastards 3 times a riding season.
Since the UniPods turned the carb access into a 2 minute job I haven't needed to clean them at all.

[Diskman01]

Pods.. I reused the long rubber intake tubes to mount the pods on. Had to trim the lip on the original intakes to accept the pods but it works great. Never looked back. Now I'm running ZR1 carbies on my 78. Fantastic mod.

[jetmechmarty]

Watch the video. It really is that simple. Fred can do anything and we know it, but he gave up on this too easily. The easiest way to have this thing running properly is with the box.

I said easest.

[timktm]

Once you do it a couple times it is actually easy. Another tip I suggest is, when you have the airbox and carb off, pre align the rubber boots on the air box to the carb. If you rotate them in the wrong direction they do not line up. Also, Wd40 is your friend, spray both boots intake and airbox. Slips right on.
Tim

[HalfCentury]

If you shove the airbox boots into the airbox, it gives you more room to remove/reinstall the carbs.

[DeanR]

Pry the upper mount (by the tank mount) forward with a screwdriver until you can get it under the tab on the frame that it bolts to. (It's flexible enough)

Push the airbox down and back as far as possible.

I struggled with the same difficulty last year.
The above tips (especially prying the upper mount) were the ticket, along with not being shy about shoving the snorkel down. Pretty dumb design.

[BA80]

Pretty dumb design.

You should try it on an XJ.

[crazy steve]

There's another variation technique that works well too...

1. Install the airbox in the chassis, push it back as far as it will go.

2. Install the carbs on the engine first. I've found that tipping the carbs back (starting the bottom edge first) then 'rolling' them 'up' into place works best. They're not going to fall in, you'll need to work at it a bit. Tighten the four boot clamps once they're in and fully seated.

3. On one side or the other, start the two carb-to-airbox boots onto the carbs. The outer one should go almost all the way on, the inner about halfway. The airbox will be crooked which is fine and don't worry about the other side yet...

4. Once you have the two boots started enough, loosely install the lower rear airbox mounting bolt on that side.

5. Move to the other side, and pull that side of the airbox forward while starting the boots. The bolt on the other side will keep that side from popping out and give you leverage to connect the other two, fully seat the boots. Install the airbox bolts and clamps and you're done!

Really, once you've managed one of these methods, you'll have a 'Well DUH!' moment...

[Prothec]

...
It started with the three Bs:- Blood, bandaids and blasphemy.
went from there to replacing the stock airbox with four UniPods.
In accordance with Finagle's law of Dynamic Negatives, while I was fighting with the stock airbox and taking some hours just to access my carbs I had to clean the bastards 3 times a riding season.
Since the UniPods turned the carb access into a 2 minute job I haven't needed to clean them at all.

The XJ airbox is no fun. New flexible rubber boots help a little.

[justinc1081]

Yup, like a lot of others i also ditched factor air box, i stole the rubber boots from the box and crammed those into some pods, made up a custom mount to help support the back of the carbs.

Taking carbs on and off is now a 5 minute process

[CaptonZap]

One thing that helps with the factory setup is to take a hair dryer and heat all the rubber parts until they are good and warm. Then a little Vaseline on the contact faces, and they practically fall together.
Takes a little time, but you can prop the dryer in position and go clean and oil the filter while you wait. (If it is the K&N type.)
CZ

[MadHatter4119]

I just spent two hour cussing this air box...gave up for today...got a late start today...will attack it tomorrow...weather permitting...Got a plan I want
to try...using a tie down strap...Its nap time now...