Stock Airbox Installation

I REALLY want to get rid of the PODs on my bike. I don't care how "cool" they look, I want the bike to run right. My thing is, I REALLY don't want to remove the motor.

Is there absolutely no way to get an airbox back on the bike with the motor in place? Obviously the carbs would have to be removed, cause I KNOW there isn't room with them on, but is there no other way? Must I remove the entire motor to put the airbox back on? (Bike was missing it, but I found a REALLY nice one on ebay for fairly cheap.)

 

Theoretically, it can't be done.

However, I have heard tales of removing carbs, starter and exhaust system and dropping the motor off its mounts forward in the frame to gain clearance.

 

I ran into the same problem. I cut my airbox in 2 pieces.... cut the square box where the filter goes cleanly off.

Then go to advanced auto and pick up some 60 second plastic bonding. Hook the front of the box to the carb, then squeeze you box inside and reconnect. when finished, take some geosil (silicone sealant) and seal it up again. This worked great for me. Just make sure you get it completely sealed up!

 

You could just strip it down, paint the frame and other parts so she looks all purdy again, tinker with a few other odds and ends and put her all back together again, only to not be able to use the starter button due to something funky with the relay.
Woa, don't know where that came from!
Seriously tho, take a deep breath and a 6 of your favourite brew, a lazy day off and take it slow, 1 step at a time. You'll have the airbox in and a great feeling of satisfaction. ^^
Warning, take it easy on the brew, or you may accidentally swap a wooden birdhouse for your airbox. Doesn't work so good. :/

 

I went with the full breakdown, pulled the engine, etc.
But when I put it back together I forgot to put the airbox back in first.
I can tell you from experience that it is possible, and is probably the most difficult thing that I've ever done in my life. The plastic of the airbox has a certain degree of "give" to it. The thin sides of the back half of the airbox will bend a little bit and will bend back. I'm not sure if I remember correctly, but you may have to remove one or two of the intake boots on the right side.

Have fun with it. Be patient. Try it a couple times a day for a week or so. You'll get it. Runs much better than PODS. (but thats a whole 'nother discussion).

 

Way back when I took mine out, then put it back in after a failed pods experiment. I wish I remember how. I think I did have the intake boots off. Everything plastic around it was off. It to 2 or3 nights of trying but I did it.

 

The easy way to remove the motor by yourself is to suspend it from an overhead mounting point several feet up, so the motor would seem to just float. Use a Come-A-Long. Check it out, in the picture the motor is one inch from being completely "in".

http://www.xjbikes.com/Forums/viewtopic ... oader.html

 

I plan to do a full breakdown and paint eventually, but right now, I wanna get the thing tuned and running enough to ride. I just need to check shims, sync carbs, and colortune, but its been 102-104 degrees down here in Houston for the past month, in the shade, and I don't have a garage to work in.

I plan to get up at the crack of dawn this weekend and try to get some stuff done. Might order an airbox off ebay just to have it around for when I do finally get to a breakdown.