Joined
·
195 Posts
Airbox removal and replacement procedure
Remove four screws attaching gas cap surround to tank, these are located at 12,3,6,and 9 o’clock positions. The remaining four screws hold surround to tank cover, they do not need to be removed, nor does the gas cap.
Raise the front of tank cover approx ½”, slide hands along both sides of tank and release from detent, approx 3” from rear of tank cover. The cover should release with minimal pressure, the detents are not but 1/8 “. Place cover in a safe area.
The airbox is held onto the tank with two bolts. There are blind nuts in tank, so you will not need a wrench or anything to hold the nut. The tank is held to the frame with a bolt vertically in the rear, and one bolt horizontally in the front.
The scoop is held in place by two screws at the rear, you can slide the electrical plug from the airbox. This is the plug for the euro version active intake valve, it is plugged in the US version.. The front of the scoop is held in place with two plastic push pins. To access the air filter the top of the airbox is removed by releasing the self tapping screws at the perimeter of the airbox.
Replacement is accomplished by fitting the rubber boot to the intake horn, and then fitting the airbox to the rubber collar. The tank is then slipped down onto the airbox and frame simultaneously. The trick here involves the ignition switch bracket on the right side of the frame, and the ignition coil bracket on the left side. The brackets have a square cutout that fits over a corresponding square tab on the frame, the tank fits outside of these brackets holding them in place on frame, the bolt goes thru all of this assembly. I found a helper to hold brackets in place while tank is lowered helps immensely.
Now just a matter of bolting and tightening all mount bolts, slipping tank cover in place, screwing surround down to retain tank cover, start and enjoy.
Remove four screws attaching gas cap surround to tank, these are located at 12,3,6,and 9 o’clock positions. The remaining four screws hold surround to tank cover, they do not need to be removed, nor does the gas cap.
Raise the front of tank cover approx ½”, slide hands along both sides of tank and release from detent, approx 3” from rear of tank cover. The cover should release with minimal pressure, the detents are not but 1/8 “. Place cover in a safe area.
The airbox is held onto the tank with two bolts. There are blind nuts in tank, so you will not need a wrench or anything to hold the nut. The tank is held to the frame with a bolt vertically in the rear, and one bolt horizontally in the front.
The scoop is held in place by two screws at the rear, you can slide the electrical plug from the airbox. This is the plug for the euro version active intake valve, it is plugged in the US version.. The front of the scoop is held in place with two plastic push pins. To access the air filter the top of the airbox is removed by releasing the self tapping screws at the perimeter of the airbox.
Replacement is accomplished by fitting the rubber boot to the intake horn, and then fitting the airbox to the rubber collar. The tank is then slipped down onto the airbox and frame simultaneously. The trick here involves the ignition switch bracket on the right side of the frame, and the ignition coil bracket on the left side. The brackets have a square cutout that fits over a corresponding square tab on the frame, the tank fits outside of these brackets holding them in place on frame, the bolt goes thru all of this assembly. I found a helper to hold brackets in place while tank is lowered helps immensely.
Now just a matter of bolting and tightening all mount bolts, slipping tank cover in place, screwing surround down to retain tank cover, start and enjoy.