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Author Topic: Installing airbox is a P.I.T.A  (Read 1649 times)

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Offline DavePhipps

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Installing airbox is a P.I.T.A
« on: October 15, 2011, 04:36:18 PM »
I bought an airbox from on of our members here (Thanks kens) and it's the first time I've tried to install one of these for years.
Man these are a PAIN!!!!!!
I've lubricated everything but I still can't get the carbs completely back on.
I'm giving up for tonight and will tackle it more in the morning.
Words of wisdom on getting these back on would be appreciated.
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Offline MCRider

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Re: Installing airbox is a P.I.T.A
« Reply #1 on: October 15, 2011, 04:42:00 PM »
Try some heat, hair dryer.
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1988 NT650 HawkGT;  1978 CB400 Hawk;  1975 CB750F -Free Bird; 1968 CB77 Super Hawk -Ticker;  Phaedrus 1972 CB750K2- Build Thread
"Sometimes the light's all shining on me, other times I can barely see, lately it appears to me, what a long, strange trip its been."

Offline WarwickE36

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Re: Installing airbox is a P.I.T.A
« Reply #2 on: October 15, 2011, 04:55:18 PM »
The airbox is easy, its those pesky carb to box rubbers!  I got the middle two through the box... 2 is easier than 3 this way.  then 1 and 4 from the outside.  I don't have fat hands though, which is nice.  install the clamps after the fact.
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" Why does anyone get offended by what someone does to their own bike? I dont get it. "

You made me think about it after I cheered knowing someone else would like to know what these control freaks are up to.
 Every time any owner strips whatever precious Honda part the horrified purists parts go up in value. That's not the part that bothers them.
 What bothers them is they sat up late at night, their breast full of wonder and estrogen, unable to sleep, dreaming about their lovely darling and all her glory... and next thing you know someone else doesn't share their emotional deluge and their reaction is they must spread their mind museum as far as they possibly can, taking over as much of the real world as possible.

Drink fast, drive slow, but ride it like you stole it

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Offline DavePhipps

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Re: Installing airbox is a P.I.T.A
« Reply #3 on: October 15, 2011, 04:59:22 PM »
I went looking through the How To section and am going to try a suggestion I found there.
I'm going to remove the battery box an back of the airbox to give more wiggle room.
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Offline WarwickE36

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Re: Installing airbox is a P.I.T.A
« Reply #4 on: October 15, 2011, 05:02:46 PM »
That part definitely helps. Getting the rubbers on isnt so bad if everything is loose.  I got new ones from david silver spares and it was about a 15 minute job.  A beer and a little cursing definitely goes a long way.  Good luck brother
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" Why does anyone get offended by what someone does to their own bike? I dont get it. "

You made me think about it after I cheered knowing someone else would like to know what these control freaks are up to.
 Every time any owner strips whatever precious Honda part the horrified purists parts go up in value. That's not the part that bothers them.
 What bothers them is they sat up late at night, their breast full of wonder and estrogen, unable to sleep, dreaming about their lovely darling and all her glory... and next thing you know someone else doesn't share their emotional deluge and their reaction is they must spread their mind museum as far as they possibly can, taking over as much of the real world as possible.

Drink fast, drive slow, but ride it like you stole it

1974 Cb550 with style
2004 SV650s

Offline Jv550

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Re: Installing airbox is a P.I.T.A
« Reply #5 on: October 15, 2011, 05:15:06 PM »
I agree it's a pain in the @$$, but so worth it if you're running pods! My 550 came with pods and it took me forever to figure out how to get the airbox in there right, but once I did, the difference was amazing - smoother throttle response, nicer sound, no more burbling on downshifts and a tiny bit better mileage. Plus with the rebreather I'm not so pollutive...
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Offline DavePhipps

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Re: Installing airbox is a P.I.T.A
« Reply #6 on: October 15, 2011, 05:15:44 PM »
I'll give an update tomorrow. After agood nights sleep a few cups of coffee and a cheap cigar, I should be ready to takcle it again.
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Offline CoachDoc

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Re: Installing airbox is a P.I.T.A
« Reply #7 on: October 15, 2011, 07:27:58 PM »
I had read the thread about removing the battery holder to make it easier to fit the carbs on/off, and I did this but on my 550 it really didn't seem to be worth the trouble. There are frame members that limit the rearwards movement of the airbox, and I really couldn't detect any improvement from having the battery holder out, PLUS putting the battery holder back was a significant PITA itself. Next time I'll skip that step definitely.
Strong +1 for heat on the rubbers. A little silicon grease really helps a lot also. I got my carbs back on in about 10 minutes- lots of wiggling while applying pressure to get the respective boots in place.
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Offline Really?

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Re: Installing airbox is a P.I.T.A
« Reply #8 on: October 15, 2011, 08:30:05 PM »
New rubber makes it really easy.  I wished my Venture was this easy.  It can take 45 minutes just getting the breather hose on.
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Offline DavePhipps

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Re: Installing airbox is a P.I.T.A
« Reply #9 on: October 16, 2011, 09:34:15 AM »
ok, been at it a bit again this morning. I can get half the of the carbs set at one time. It's like playing whack a mole with carbs. one side in the other side pops out.
I'm going to the store get some OJ and the ultimate rubber lubricant ArmorAll
Don't put that stuff on your seats kids :)
I fell for that my first year of riding.
« Last Edit: October 16, 2011, 09:35:53 AM by DavePhipps »
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Offline DavePhipps

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Re: Installing airbox is a P.I.T.A
« Reply #10 on: October 16, 2011, 11:24:57 AM »
Found out the intake manifold rubbers were hard as rocks. Thankfully I have spares that were much softer.
I cleaned them up and gave a good wipredown with armor all and they carbs went onto the intakes in about 10 seconds :D
I'll post some pics later if I can find my camera.
You guys have to see the electrics on this one. The PO installed a Ricks motorsports RR :)
He also butchered the wiring :(
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Offline DavePhipps

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Re: Installing airbox is a P.I.T.A
« Reply #11 on: October 16, 2011, 02:52:30 PM »
Sorry guys. The camera has gone AWOL.
I will say that during my test ride the bike is even worse on at all throttle openings.
The only change I made was setting float levels to 22mm and opening air screws 2.5 turns out.
Then again the engine needs lots of work so nothing is conclusive right now.
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Offline DavePhipps

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Re: Installing airbox is a P.I.T.A: Rat nest elect pic included
« Reply #12 on: October 16, 2011, 04:49:12 PM »
Here's where the electrical panel should be.
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Bikes:
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