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WTF Air Box?!?

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WTF Air Box?!?
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Joined: 24 Aug 2016
Posts: 8
Location: Inland Northwest, USA

Post WTF Air Box?!? Reply with quote
So, after searching around to no avail for a schematic, I decided to pull my air box out today. 'Cause I had dropped a few fasteners inside the cavity whilst poking about. Attention fellow newbs - this machine has the most absurd air box securement of anything I've worked on (H-Ds, Hondas, a 1965 Triumph Spitfire {car}, Suzukis, countless 1970's land yachts, you get the idea). So, before you loose your mind like I almost did, here's what I've discovered as the only way to remove the air box (as relative to my 05 Chetak):

Pull the gas tank
Remove the engine cowling
Remove the only obvious bolt, which is on the engine side, rearward, lined up with the carb and close enough to the carb to make grabbing it with a wrench difficult, but no impossible
Lift the bike (no, really). I used my Orly bike lift, a life saver.
Find the 2 bolts that you can see on the underside of the fender, against what would be the outside of the body cavity. OR, pull the rear wheel, which adds more time to what should be an easy task in a sane universe but gives easy access.
Use a socket drive to remove these. Handle pointed up towards the seat, then inch it back and forth.
Decide if those bolts are providing any extra value to the unstressed plastic box which is safely held in place within the body of the machine. Act accordingly.
Lower the lift.
Move to the engine side, locate the (3?) screws that hold the forward plastic engine cowling in place, remove them.
Pull the plastic cowling off. Try not to loose temper due to exasperation at this point.
Find the last bolt. You won't have a wrench that can reach it due to the sheet metal angles.
Get a needle nose vice grip (VERY IMPORTANT). Use this to loosen the bolt by minimal increments until you can run it the rest of the way out by hand. Pay this bolt the same consideration you did the 2 behind the body cavity/in front of the rear wheel.
Back to the body cavity - loosen any hoses still attached to the air box. Realize that the bizzaro fitment from the air box to the duct work that leads to the carb may need to be removed. Loosen/remove as needed.
Pull the box out, recover whatever you dropped into the body cavity, then reassemble to whatever extent you deem necessary.

After 25 years of wrenching on just about everything, the fact that it takes almost 2 hrs to figure this out and do it blows me away. Not only is it over the top, but considering a gnat fart can strip out the oil drain plug but the air box could survive a crash with a semi, I've got to question the overall aptitude of the original engineers on this thing.

Scotch now, first attempt at starting the bastich up tomorrow.

Does anyone know why the air box should be secured like Fort Knox?

2005 Chetak with a Cosi Sidecar!
Mon Apr 10, 2017 1:45 am View user's profile Send private message
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