What's the deal with this air box?

[zolck510]

This isn't what I expected to see. It's an '08 250. All of thr photos and videos I've seen for the air box mod to make the carb work easier shows the airbox and the battery box attached to each other. My battery box is a completely separate piece and this airbox looks smaller. It also does not move, making putting the carb back in nearly impossible right now... Any and all help appreciated.

[adouglas]

Been some years since I did my jets, but IIRC the easiest way to get the carbs out is to loosen the rubber inlet tubes, and pull them forward and out through the left side of the frame. Sorry, can't be more specific than that... going entirely off of memory.

[zolck510]

seems like much of the wiki was written on the pregen and does not reflect the new gen config. it is an absolute pain right now just trying to put the carb back on. can somebody please give me some tips? i'm nearly about to lose my mind.

[csmith12]

I did this a while back, maybe I should do a better one. Mr. Fist is right though, you just wrestle them out the side of the frame.

Link to original page on YouTube.

[zolck510]

Sorry, I was unclear with my original post. Wrestling it out of the side is how I got it out. What I'm having mega trouble with now is trying to put it back in.

[adouglas]

Again, going from dim, faulty memory, so this may be completely wrong.... As I recall the biggest issue is getting the carbs, rubber inlet tubes and airbox all lined up. Instinct is to mount the tubes at one end first, then try to get the carbs in and lined up. There isn't room to do this.

I think that what I did was to undo the mountings for everything (both ends of the tubes) so that I could move them around more... as in, they're in place but not locked down at first. Once everything is where it's supposed to be, then retighten. Don't forget to leave the hose clamps on the tubes.....

It's possible I also undid the airbox mounting bolts to let it move as well. Not sure about that, though.

The overall objective here is to get everything mated (engine/tubes/carbs/airbox), then secure the whole mess.

[CZroe]

I can't help but read this thread title in Jerry Seinfeld's voice.

[rc racer]

With the battery and battery box removed you should be able to slide the airbox back about an inch. Might also have to loosen some hardware for the under tail. Still difficult but much easier to slide the carbs back into the boots.

[Racer x]

The battery is attached to the air box up to 07 then the 08 has it seperate.

There are other ways of doing it. But if I have to pull the carbs from a stock bike . I start by removing the rear wheel. Drop the rear belly pan and slide the air box back. Seems like a lot of work. But I timed it once and did it in an hour. Plus the carb work. It's hard the first time finding all the little screws.

[zolck510]

ok, got the carb back in. now i'm having trouble with lining up the airbox with the carb. the carb cant move since the engine intake connection is clamped. the airbox connection just does not want to sit in the boot. its like the airbox isnt coming forward enough. im sure i pusged it back in place, with the tube going through the grommet in the upper right.

[spooph]

Remove the exhaust mount/passenger peg bracket on the right side of the bike (as if you're sitting on the bike). There is a little screw just behind it which holds the air box in place. If you remove this bolt, the airbox can move a bit more...


Getting the carbs back in the quickest way:

1.) Verify you have the hidden bolt behind the exhaust/passenger peg mount removed, along with the bolt which bolts to the tank mount (as is shown in your pictures above.
2.) Wiggle the carbs into the airbox side first - this is usually made easier by complete removing the bolt for the metal clamps. One the carbs slide into these boots, clamp them down. It might also be made easier if you remove the coolant overflow reservoir on the right side of the bike.
3.) With the carbs attached to the airbox, slide them into the engine side rubber boots.
4.) Re-attach the airbox to the gas tank mount and the hidden bolt behind the exhaust/passenger peg bracket.
5.) Tighten down the engine side rubber boot clamps.

I can have the carbs in and out in about 30 min using this technique, although it will be easiest by far with Racer X's method of remove the rear wheel and fender.

Hope this helps.

[zolck510]

I wasn't aware that there was a hidden bolt behind the passenger peg! I removed two bolts from the airbox. One from the gas tank mount (right side above the box) and one from underneath on the left side. I'll find that hidden one and hopefully things will move better. Right now I have it set up such that the carb is already connected to the engine side boots and I'm trying to wiggle the airbox boots to fit with the carb. I'll have to re-disconnect the carb from the engine boots to fit the airbox boots first then push it forward.

[Racer x]

Make sure the clamp screws are open enough to slide on easy. Also maybe some WD 40