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Old March 20th, 2017, 02:05 PM   #1
Triple Jim
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Airbox Brackets After Battery Box Separation

I recently separated my battery box from the airbox, using a hacksaw blade in a small handle. I was able to do it without taking the airbox out by temporarily moving the coolant tank and electrics out of the way. For the first time since I got the bike a year and a half ago, I was able to get the rubber boots all the way on the carbs.

The trouble was vibration could cause the boots to wander back off the carbs. Maybe screw type band clamps would prevent that, but with the battery hold down strap in place, it would always be pulling back on the airbox, trying to move it off the carbs. I didn't want to just leave the strap off, since it holds the airbox lid in place, which in turn holds the filter retainer in place.

So I made a couple little aluminum brackets that have that have slotted holes at the frame end, and use two sheet metal screws each to connect to the airbox. I shoved the airbox forward and tightened the bolts, and I don't think the airbox will try to wander off the carbs.

I'm probably not the only one to do something like this, but I thought I'd post a photo of the brackets in case it might help someone else. I suggest using a small hot nail to make pilot holes for the screws if needed, since drilling might leave debris inside.

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Old March 27th, 2017, 07:21 PM   #2
Ram Jet
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Originally Posted by Triple Jim View Post
I recently separated my battery box from the airbox, using a hacksaw blade in a small handle. I was able to do it without taking the airbox out by temporarily moving the coolant tank and electrics out of the way. For the first time since I got the bike a year and a half ago, I was able to get the rubber boots all the way on the carbs.

The trouble was vibration could cause the boots to wander back off the carbs. Maybe screw type band clamps would prevent that, but with the battery hold down strap in place, it would always be pulling back on the airbox, trying to move it off the carbs. I didn't want to just leave the strap off, since it holds the airbox lid in place, which in turn holds the filter retainer in place.

So I made a couple little aluminum brackets that have that have slotted holes at the frame end, and use two sheet metal screws each to connect to the airbox. I shoved the airbox forward and tightened the bolts, and I don't think the airbox will try to wander off the carbs.

I'm probably not the only one to do something like this, but I thought I'd post a photo of the brackets in case it might help someone else. I suggest using a small hot nail to make pilot holes for the screws if needed, since drilling might leave debris inside.

Nice work on the brackets!! I don't know why you wanted to separate the battery box from the airbox main unit but I'm sure you had a good reason. Oh, I think I get it - to help prevent the airbox from separating from the carb inlets.

If you have to drill into an area where you don't want drill chips left behind coat your drill with grease (wheel bearing?), and the grease should capture the drill shavings.
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Old March 27th, 2017, 08:57 PM   #3
Triple Jim
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It's a well known mod that allows you to remove the battery and its separated section, slide the airbox back, and get much better access to the carburetors when needed. In my case, I've had quite a bit of trouble getting the airbox boots to stay mated with the carb mouths, because it appears things have shrunken and/or warped a little in the 12 or 13 years since my 250 was made, and the separation made it hugely easier to get things to stay together.

I'm old, or at least not so young, and know about the grease on drill thing, but I do appreciate your taking the time to mention it. I've found it works OK sometimes, or at least is better than nothing. I think in the case of this airbox, a hot nail or similar object would be a better idea. It might even leave the plastic a little thicker in the immediate area to give the screw a good bite.
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Old March 27th, 2017, 10:58 PM   #4
Ram Jet
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Originally Posted by Triple Jim View Post
It's a well known mod that allows you to remove the battery and its separated section, slide the airbox back, and get much better access to the carburetors when needed. In my case, I've had quite a bit of trouble getting the airbox boots to stay mated with the carb mouths, because it appears things have shrunken and/or warped a little in the 12 or 13 years since my 250 was made, and the separation made it hugely easier to get things to stay together.

I'm old, or at least not so young, and know about the grease on drill thing, but I do appreciate your taking the time to mention it. I've found it works OK sometimes, or at least is better than nothing. I think in the case of this airbox, a hot nail or similar object would be a better idea. It might even leave the plastic a little thicker in the immediate area to give the screw a good bite.
Good point about the hot nail, it doesn't remove much material - like a drill does. Old my tail feathers, I'm 68 and I just learned about hot nails. :-) My bike is 10 years old. I better check to make sure the airbox is still connected to my carb intakes. Good time to check because nearly all of my fairing components are off the bike. This is my first full fairing bike and I'm not sure I like all the plastic junk between me and my engine - looks cool though.
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Old March 28th, 2017, 06:39 AM   #5
Triple Jim
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I didn't care for the looks of the fairings on pregen 250s when I was thinking of buying one, so I had already planned to take them off while I was shopping. There are different ways to go about it... my goal was to not run the cost up any more than necessary. There are quite a few threads with photos of naked 250s around. Here's one. Mine is the red one.

https://www.ninjette.org/forums/showthread.php?t=283678
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Old October 7th, 2019, 06:26 AM   #6
Triple Jim
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Here's the photo without Photobucket's blurring service added:
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File Type: jpg ex250_airbox_brackets.jpg (165.7 KB, 19 views)
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