Topic: Need the process for re-installing air box. UPDATED PICS

[Chris Liston]

I'm currently running pods but am thinking of putting an airbox back on.  Looks like a real PITA as you have to bolt the box in with boots and then put carbs back on and I guess twist and shout the boots back over the carbs.

Does anyone have a specific process they use to do this thats easy?  Or is it always a pain.

Here are pics of the setup I'll be using.  I got it on ebay last year for $20 bucks.


Thanks

[eldar]

Split the box in half and install the top half first. Then with the filter in the bottom half, put that on and tighten the bolts. It can go on as one unit but is a REAL pain.

[bowhunter]

Always a Royal Pain! Install the top half first. Make sure the clamps are loose to the point of falling off. Slide the upper housing into place under the carbs and hook up any hoses. Alighn the four carb boots at the bottom of the venturies. Tilt the airbox up onto the carbs while shifting it side to side and up and down. Use a long common screwdriver to assist the boots in alighning with  the openings.
After doing this a dozen times or so, it becomes second nature! Tighten tthe clamps when the boots are fully seated, attach the lower half, then screw the whole airbox to the frame.

Have Fun :

[Buffo]

If the boots are not on the carbs all the way when you tighten down the clamps, the clamps will not sit on enough of the carbs and when tightened will pull the boots off.  Make sure the boots are all the way on and then some. Make sure all is well when finished.

I have to put my box on with the carbs off of the engine. I couldn't get it on PROPERLY with the carbs attached. But I am a little picky.

Don

[Jonesy]

I install the upper airbox (sans filter case) first. I spray a bit of silicone spray on my finger and apply a slight film in the flanges of each velocity stack. Then, I work the airbox into position, and with my fingers reach up into the airbox and push on each stack to help it onto the respective carb.

[Chris in Ramsey]

We'll assume that you are asking for help on your CB550, so the replies that include the step of putting in the top half first won't quite work, eh? You'll have to remove the carbs first and then install the filter box followed by the air box. Bolt the two boxes together, but leave the assembly loose in the frame. Put the carb to air box rubbers inside the air box, then install the carbs to the engine and working from the center out, fit the carb to air box rubbers. After you do this 40-50 times you can easily do it in 7 hours 

[Jonesy]

We'll assume that you are asking for help on your CB550...

Oh.. Ooops!

[Buffo]

Just took for granted that everyone had the same bike I did. 

Don

[Chris Liston]

Sorry guys.  Its a 550.   Actually the only piece of the airbox I'm going to use is the part that mounts to the carbs.  I picked up this neat K&N cone filter assembly that actually mounts to the intake part of the box.  So its carbs--->intake portion of airbox---> metal flange to K&N cone filter.  Got it on Ebay for 20 bucks last year and just getting around to mounting it.  I'll take some pics of the setup. 

thanks.  All other 550 procedures welcome

[spaceboy412]

could you post a pic of that, i would like to see that setup.

[cb750ian]

I just did mine on a 1974 750.
The rubber boots bend and fit easier if you heat them in warm water before installation.Yes,you split the airbox,then take the rubbers out to soak them.Reinstall and do up clamps on each carb.You can play with the Boot spacing before you bolt the top airbox to the frame. Then install the two 10mm bolts.
Good luck,

[rt]

since i dismantled/refitted my first 550 airbox a couple of years ago  i'm convinced those japs originally held an airbox in mid-air and constructed the frame around it.... my latest attempt to solve the problem was with carbs in situ: unbolt/remove battery-box and sqeeze in airbox from the right hand side (some serious swearing at this stage does help), adjust (don't forget to put those clamps on), re-install filter box and battery holder, sit back and have a beer (or three). if you've done that a couple of times, you may do it in less than five hours (chris in ramsey - eat your heart out :-) ). either way it's a real pain but can be done without cutting the frame. 

[Chris Liston]

bounce for the pics

[Einyodeler]

Hi Chris
Here`s a handy little tip for the 500/550 airbox plenum. The rubber boot on the left is how it`s attached , just push them in like the one at the right and when you get it in place pull them back out. You won`t believe what  a difference that 3/4 of an inch makes

[Tim.]

Hi Chris
Here`s a handy little tip for the 500/550 airbox plenum. The rubber boot on the left is how it`s attached , just push them in like the one at the right and when you get it in place pull them back out. You won`t believe what  a difference that 3/4 of an inch makes

You make it sound like pulling the boots back out when the carbs are in place is an easy task?  I've never done it, but will be swapping out my carbs soon, so will be in this boat too.  How do you pull the boots back out once the carbs are in place?  They'd have to be a pretty loose fit (too loose) to simply slide over the carb intakes.

[Chris Liston]

Great install idea.  I bet by pushing the boots in the carbs almost just slide right in.  Its too bad we have to remove the carb bank to install the plenum. 

[Einyodeler]

Hi Chris
Here`s a handy little tip for the 500/550 airbox plenum. The rubber boot on the left is how it`s attached , just push them in like the one at the right and when you get it in place pull them back out. You won`t believe what  a difference that 3/4 of an inch makes

You make it sound like pulling the boots back out when the carbs are in place is an easy task?  I've never done it, but will be swapping out my carbs soon, so will be in this boat too.  How do you pull the boots back out once the carbs are in place?  They'd have to be a pretty loose fit (too loose) to simply slide over the carb intakes.

The boots are pushed in just to make the carb bank installation easier,once you have the carbs installed the plenum still has enough movement to get at the boots and then you can pull them right back out.

[Chris Liston]

Yodler,

Would you suggest softning the boots as mentioned earlier in the post by soaking them in warm water to soften them?

[eldar]

Now that airbox looks interesting. I think I kinda like it. 

[Chris Liston]

Hopefully it will do the trick.  I'm running alittle lean with the pods.  I plan on adapting the stock air filter housing to let the K&N cone fit into it.  Maybe over the weekend I'll get going on it.

[Gregorymoto]

Good luck. that is where i started taking #$%* off and throwing it out with the solid idea that there were of bad engineering design.

[Flood]

Would you suggest softning the boots as mentioned earlier in the post by soaking them in warm water to soften them?

Soaking in warm water is a good idea. Soaking in Armor All helps even more. My trick is to warm them with a hair drier, but be careful with the hot wires and the gas tank/carbs etc.