In all the reading i did before attempting re-jet, i don't recall mention that the stock airbox carb combo is an absolute PIA ! to get back together.

Anybody else have problems lining up the effing velocity stacks (? ! )  and having them seat correctly, so the clamps which i can barely get a driver on, will clamp in exactly the right place ? ?

I was tempted to just leave the box off ( rubber velocity stacks !  cool !) but then my new unifilter would go to waste and i'm sure the thing would run like crap.

I did try different ways of putting it back together, with carbs attached,  and with carbs already installed on the bike, and wrestling the rubber boots from inside the box, and outside.  must be some trick to it.

But it's back together, finally.  Just wondering for when i have to do this again.

The best way I found was with the carbs attached to the air box  Its still a pain but what are ya gonna do 

Spray some WD40 on the inside of the boots before assembly.  Then use a BLUNT screwdriver to help slide the boots all the way seated.  A sharp screwdriver and you'll tear the boot.  Use one that has been abused to within an inch of its life (most of mine look that way eventually).

The air box can be removed with the air filter in it, but you'll never be able to get it back on without getting the filter out and using your hands inside the airbox to open up the boots inside out, and I use fingers not a screwdriver.
I'd also swap the manifold boots for hex heads, so I can get the boots and carbs off without taking the air box out of the bike. Just push it back to the battery box, and undo the manifolds and lift the carbs and cables etc straight up and out. Route your cables on top of the T brace on the frame too, so you can have the carbs with cables still attached and just work it that way.
Trust me, its not getting back on with the filter still there, and this is the second easiest bike to get air box and carbs off. the easiest I have seen is a seca 2, its air box splits in 1/2 and carbs are down draft. Inspite of being a 4 cyl, you just toss in the carbs, and press straight down and they are on. Repeat with the lower 1/2 of air box, then put the top 1/2 in.
Cool.
Buddha.

I  have never had trouble installing the air box. I usually make sure the rubber boots on the air box are in the box correctly. THen with airfilter in box, and carbs attached to engine  I slid the airbox in so the boots are shooting at about a 45 degree angle to the ground and as it goes in turn the air box to its proper position. I am assuming you removed the tank.

Quote from: seshadri_srinath on February 10, 2008, 05:40:12 PM
The air box can be removed with the air filter in it, but you'll never be able to get it back on without getting the filter out and using your hands inside the airbox to open up the boots inside out, and I use fingers not a screwdriver.
I'd also swap the manifold boots for hex heads, so I can get the boots and carbs off without taking the air box out of the bike. Just push it back to the battery box, and undo the manifolds and lift the carbs and cables etc straight up and out. Route your cables on top of the T brace on the frame too, so you can have the carbs with cables still attached and just work it that way.
Trust me, its not getting back on with the filter still there, and this is the second easiest bike to get air box and carbs off. the easiest I have seen is a seca 2, its air box splits in 1/2 and carbs are down draft. Inspite of being a 4 cyl, you just toss in the carbs, and press straight down and they are on. Repeat with the lower 1/2 of air box, then put the top 1/2 in.
Cool.
Srinath.

thats the easyest way !!!!!

Quote from: seshadri_srinath on February 10, 2008, 05:40:12 PM
The air box can be removed with the air filter in it, but you'll never be able to get it back on without getting the filter out and using your hands inside the airbox to open up the boots inside out, and I use fingers not a screwdriver.
I'd also swap the manifold boots for hex heads, so I can get the boots and carbs off without taking the air box out of the bike. Just push it back to the battery box, and undo the manifolds and lift the carbs and cables etc straight up and out. Route your cables on top of the T brace on the frame too, so you can have the carbs with cables still attached and just work it that way.
Trust me, its not getting back on with the filter still there, and this is the second easiest bike to get air box and carbs off. the easiest I have seen is a seca 2, its air box splits in 1/2 and carbs are down draft. Inspite of being a 4 cyl, you just toss in the carbs, and press straight down and they are on. Repeat with the lower 1/2 of air box, then put the top 1/2 in.
Cool.
Srinath.

I did eventually figure out that the filter should be removed to work from the inside - but I have to do most things the hard way first for some perverse reason.

What's a 'hex head' that replaces the rubber intakes ?

different clamps on the boots ,prob??? simmilar to a hose clamp

Quote from: The Buddha on February 10, 2008, 05:40:12 PM
The air box can be removed with the air filter in it, but you'll never be able to get it back on without getting the filter out and using your hands inside the airbox to open up the boots inside out, and I use fingers not a screwdriver.

I really wish I knew this yesterday!  I struggled so much w/ that stupid air box.  I was going to go back in this weekend, but was dreading getting the airbox back on.  Using that method should make it much easier.

Hex head bolts on the engine manifolds instead of stock screw heads.
Cool.
Buddha.

Quote from: VSG on April 07, 2008, 12:09:23 PM

Quote from: The Buddha on February 10, 2008, 05:40:12 PM
The air box can be removed with the air filter in it, but you'll never be able to get it back on without getting the filter out and using your hands inside the airbox to open up the boots inside out, and I use fingers not a screwdriver.

I really wish I knew this yesterday!  I struggled so much w/ that stupid air box.  I was going to go back in this weekend, but was dreading getting the airbox back on.  Using that method should make it much easier.

you generaly find these things out after pissing around with the jetting on the carbs and have everything in and out a million times !!!

I see that this is an old thread that was revived, but my solution to the air box problem was to put it on a shelf in my basement with the rest of the crap I yanked off of my bike. 


i.e.; K&N lunchbox.   

Quote from: Teek on April 07, 2008, 10:27:36 PM
I see that this is an old thread that was revived, but my solution to the air box problem was to put it on a shelf in my basement with the rest of the crap I yanked off of my bike. 


i.e.; K&N lunchbox.   

= price-less