Air Box Installation on 2007 Ninja

burnrich · January 25th, 2014, 12:55 AM

Has anybody had a good time trying to re install air box after re installing carbies? I'm having a bitch of a time trying to get the ports to slip over the intake ports on the carbies let alone put the springs on and try to slip the ports over the caribes. Have given up on it today as there is very limited space to slip them on without the bottom of the rubbers catching on the carbies and giving me the McSh*ts.

Any inspiration would be appreciated.

Midnight_tinkerer · January 25th, 2014, 02:00 AM

I usually leave the springs on, but roll them back away from the opening. Push the airbox forward until at least one part of each rubber has slipped over the carb lip. Then use a torch and a long thin flat blade screwdriver to coax the rest of the rubber to slip onto the carb. Sometimes heating the rubbers with a hair dryer softens them making the job a little easier. By far the biggest help is to fit new rubbers, as they shrink & stiffen with age, getting harder with each passing year to fit, until they become impossible.

burnrich · January 25th, 2014, 03:54 AM

Quote:

Originally Posted by Midnight_tinkerer

I usually leave the springs on, but roll them back away from the opening. Push the airbox forward until at least one part of each rubber has slipped over the carb lip. Then use a torch and a long thin flat blade screwdriver to coax the rest of the rubber to slip onto the carb. Sometimes heating the rubbers with a hair dryer softens them making the job a little easier. By far the biggest help is to fit new rubbers, as they shrink & stiffen with age, getting harder with each passing year to fit, until they become impossible.

Thanks mate that's given me a few ideas to attack it tomorrow with. I'd have to say that it's probably the worst airbox design I've come across but I've only ever worked on a hand full of bikes.

n4mwd · January 25th, 2014, 07:00 AM

I'm thinking you guys are in Australia or something. When you said "Torch" it means something totally different here in the US.

As far as the stiff rubber, I have heard of people spraying them down repeatedly with tire grease - that stuff people use to shine their car tires. It soaks in to the rubber and can make it come back a little.

burnrich · January 25th, 2014, 03:22 PM

To add to my woes I decided it was far far easier to just take the rear fender off so I could just slide the airbox back and reattach the springs in the correct position and ensure this woeful design of an airbox is properly fitted to the carbs. Anyway on pulling off the gearbox breather tube I noticed that the air filter oil (lacking the distinct viscosity of most air filter oil) has started to leak into the bottom of the air box and down the breather tube and into the F**CKING gearbox. I'm starting to think a set of K&N pod filters with some serious rejetting and some aftermarket pipes is the way this project is headed.

Anybody know is overdosing on filter oil and having this problem will affect gearbox performance?

n4mwd · January 25th, 2014, 06:56 PM

The breather tube can splash oil into the airbox. This starts happening about 7000 RPM. So its probably that which you saw and you want it to go back to the engine. But a lot of it ends up getting sucked into the engine.

If you haven't already, you might want to look at my video on removing the carbs in 6 minutes. It might help answer some questions.

Link to original page on YouTube.

burnrich · January 25th, 2014, 07:31 PM

Quote:

Originally Posted by n4mwd

The breather tube can splash oil into the airbox. This starts happening about 7000 RPM. So its probably that which you saw and you want it to go back to the engine. But a lot of it ends up getting sucked into the engine.

If you haven't already, you might want to look at my video on removing the carbs in 6 minutes. It might help answer some questions.

Link to original page on YouTube.

I think my issue was too much crap quality air filter oil which then subsequently drained into the bottom of the airbox and has been sucked into the gearbox breather vent hole. Is that what your talking about?

n4mwd · January 25th, 2014, 08:16 PM

Quote:

Originally Posted by burnrich

I think my issue was too much crap quality air filter oil which then subsequently drained into the bottom of the airbox and has been sucked into the gearbox breather vent hole. Is that what your talking about?

I doubt it will hurt anything.

burnrich · January 25th, 2014, 09:19 PM

Quote:

Originally Posted by n4mwd

I doubt it will hurt anything.

Thanks for that. The video you made is exactly how I removed the air-box (i.e. the proper way.

burnrich · January 25th, 2014, 10:47 PM

Quote:

Originally Posted by Midnight_tinkerer

I usually leave the springs on, but roll them back away from the opening. Push the airbox forward until at least one part of each rubber has slipped over the carb lip. Then use a torch and a long thin flat blade screwdriver to coax the rest of the rubber to slip onto the carb. Sometimes heating the rubbers with a hair dryer softens them making the job a little easier. By far the biggest help is to fit new rubbers, as they shrink & stiffen with age, getting harder with each passing year to fit, until they become impossible.

Thanks for your input. The only successful way to install the carbs and air box is how n4mwd has describedf it in his video. I used his method and everything just slides on with minimal effort. If you try to do it any other way it will just take longer and create more work IMO.

agentbad · January 26th, 2014, 03:03 PM

There's always pods.

burnrich · January 26th, 2014, 03:49 PM

Quote:

Originally Posted by agentbad

There's always pods.

Yeah but I've read mixed reviews about installing pods. Plus there is the rejetting and zorst extra $$$. I just don't think it's worth it on this bike. Sure the GPX is a trusty stead and I actually bought one with a full license and my days of riding power are over and I just want a nice simply easy to maintain machine that's good for commuting.

Also once you actually install everything in the correct order the correct way it's relatively easy. The first sign that something didn't fit correctly and I just left the bike and came back to it the next day after doing more research and sure enough I was installing it wrong every time and blind rage just gets in the way of a good install every single time.

agentbad · January 27th, 2014, 01:47 PM

I am actually thinking of going to EFI because I am tired of messing with carbs and I want something that's adaptable to different altitudes and climates.

Midnight_tinkerer · January 27th, 2014, 03:37 PM

Quote:

Originally Posted by n4mwd

I'm thinking you guys are in Australia or something. When you said "Torch" it means something totally different here in the US.

Yes it's hard for us to decipher some of your terms too.

AUS < > USA

Torch = flashlight
Fuel / petrol = Gas
Gas (LPG) = ??
Fuel tap = Petcock

Perhaps there needs to be a thread listing all the different terminology?

n4mwd · January 27th, 2014, 04:41 PM

Quote:

Originally Posted by Midnight_tinkerer

Yes it's hard for us to decipher some of your terms too.

AUS < > USA

Torch = flashlight
Fuel / petrol = Gas
Gas (LPG) = ??
Fuel tap = Petcock

Perhaps there needs to be a thread listing all the different terminology?

fuel/Gas/gasoline for the car/lawnmower is petrol
gas for the house/torch is LP gas/natural gas/butane gas/acetylene gas
Fuel taps don't have petcocks, but petcocks are also a valved fuel tap.

January 25th, 2014, 12:55 AM	#1
burnrich ninjette.org member Name: Peter Location: Melbourne Join Date: Dec 2013 Motorcycle(s): gpx 250 Posts: 85	Air Box Installation on 2007 Ninja Has anybody had a good time trying to re install air box after re installing carbies? I'm having a bitch of a time trying to get the ports to slip over the intake ports on the carbies let alone put the springs on and try to slip the ports over the caribes. Have given up on it today as there is very limited space to slip them on without the bottom of the rubbers catching on the carbies and giving me the McSh*ts. Any inspiration would be appreciated. __________________________________________________ "Revenge is so very, very sweet"

January 25th, 2014, 07:00 AM	#4
n4mwd ninjette.org certified postwhore Name: D Location: Palm Beach, FL Join Date: Oct 2010 Motorcycle(s): 2006 Ninja 250R, 2007 EFI Ninja 250R Posts: A lot. Blog Entries: 1	I'm thinking you guys are in Australia or something. When you said "Torch" it means something totally different here in the US. As far as the stiff rubber, I have heard of people spraying them down repeatedly with tire grease - that stuff people use to shine their car tires. It soaks in to the rubber and can make it come back a little. __________________________________________________ My Ninja Blog Proud member of ABATE.My NYC Road Rage documentary - CENSORED!

January 25th, 2014, 03:22 PM	#5
burnrich ninjette.org member Name: Peter Location: Melbourne Join Date: Dec 2013 Motorcycle(s): gpx 250 Posts: 85	To add to my woes I decided it was far far easier to just take the rear fender off so I could just slide the airbox back and reattach the springs in the correct position and ensure this woeful design of an airbox is properly fitted to the carbs. Anyway on pulling off the gearbox breather tube I noticed that the air filter oil (lacking the distinct viscosity of most air filter oil) has started to leak into the bottom of the air box and down the breather tube and into the F**CKING gearbox. I'm starting to think a set of K&N pod filters with some serious rejetting and some aftermarket pipes is the way this project is headed. Anybody know is overdosing on filter oil and having this problem will affect gearbox performance? __________________________________________________ "Revenge is so very, very sweet"

January 25th, 2014, 06:56 PM	#6
n4mwd ninjette.org certified postwhore Name: D Location: Palm Beach, FL Join Date: Oct 2010 Motorcycle(s): 2006 Ninja 250R, 2007 EFI Ninja 250R Posts: A lot. Blog Entries: 1	The breather tube can splash oil into the airbox. This starts happening about 7000 RPM. So its probably that which you saw and you want it to go back to the engine. But a lot of it ends up getting sucked into the engine. If you haven't already, you might want to look at my video on removing the carbs in 6 minutes. It might help answer some questions. Link to original page on YouTube. __________________________________________________ My Ninja Blog Proud member of ABATE.My NYC Road Rage documentary - CENSORED!

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agentbad ninjette.org sage Name: bob Location: Earf Join Date: Apr 2013 Motorcycle(s): 2005 Ninja 250, 2006 SV650N Posts: 642	I am actually thinking of going to EFI because I am tired of messing with carbs and I want something that's adaptable to different altitudes and climates.