New airbox how easy to fit?
 

well the carbon airbox has been sitting gathering dust in the garage, the weather forecast does n't look good for the weekend so perhaps I should spend some time and get it on?
I've got my Haynes book, is there anything else I should know before I start? Not sure that I want to unplug the alarm, so can I leave the seat attached, and still get the tank off? How long should it take me?

Ian, dont do it. They look rubbish, and are really hard to fit. I'll take it off your hands for £50, oh go on then £60.

lol, lucky man it will look great once on.

:lol::lol:

i thought when i saw the reply, good, somebody is going to tell me it's a 5 minute job.

Carbon air tubes next, a hugger, black frame plugs, then what?

You\'ll have trouble with Weeksy\'s directions.....
 

If you dont remove the 4 airbox fixing screws before you try to remove it!!!;)

There's also an oil breather pipe that connects to the airbox that you'll need to pull out.

You'll need to remove the seat to get good access to the tank fixing bolt at the back of the tank.

It is a pretty straightforward job, just give yourself 1/2 hour or so, follow Weeksy's directions, read the manual first and give it a go.

Also, when you're putting the tank back on, be sure to put a dab of grease around the o-rings on the fuel union connectors, this'll reduce the risk of damaging these o-rings.

Good luck
Tim

You'll still have problems if you leave the two remaining airbox screws in place.......there are 6 :roll::P

good advice with the grease on the fuel connector seals though.
might still be worth getting a couple of new ones "just in case"
Before you screw the tank down though, lift it slightly, turn on the ignition a couple of times and look for any leaks with the fuel system pressurised.

Doh!!!!!!
 

Come on guys it isn't that hard-I had to remove the airbox on my old 996 at the side of the road in the Appenines...............
Anthony the muppet-who now owns it-had dropped the key down the side of the tank and the only way to get to it was to remove the tank and airbox. We even managed it with the standard tools in the toolkit!:lol:

John

thanks guys, helpful as ever, - i thought the weeksy description looked too simple, I smell a rat though, - each of you take turns to lull me into into a false sense of confidence by first making it sound easy, - and then more bolts, - and then more, - are you sure there are no rivits in there? So Ok the job is on this weekend, - I can tell the wife " i am just out in the garage, back in half and hour".

and big thank you to Nelly for getting me the Shell oil, - wonderful service. I should have come to you in the first place, - and spent the hours that i was driving between Shell garages doing the airbox instead???!!

I cant remember exactly if you have to remove the metal spring clips from the old airbox or the old airtubes when you replace them with the carbon items.....it was a few years ago when I fitted both carbon airbox and tubes....

He, he quite funy reallly coz now you dont know whether youll need a drill, a 3 or 4 mil drillbit, a pop-rivet gun and four pop-rivets (or is that 8 pop rivets)!!:roll:

Air boxy thingy removal!
 

If its any help I removed the airbox from my 998s so that I could fit carbon air tubes and a JHP under tank filter system and had no problems at all (removing the box that is!) but I would advise you to remove the seat as weel just to give better access.

If anybody needs my thoughts on fitting the above, please ask as it was quite an interesting experience.:o

Ian.....
 

Does the carbon airbox have the clips for the airtubes already fitted?

If so, then you're fine, if not, you'll need to remove the clips from the original airbox and fix to the new, or get some new clips.

But as these are rivetted on, then they should be fitted to the new airbox already.

Just give yourself plenty of time and you'll be fine, worse case is you'll have to leave her as she is for a while, but you'll have learnt a lot about changing it when you can change this.;)

Tim

Ooops, Did anyone also mention the rubber seal for the tank that is sometimes glued on. This will have to transferred across as well or buy a new one.....:frog:

carbob air box
 

One word of warning, if you have to transfer & rivet the air tube retaining clips onto the new box be careful as carbon can shatter, take it slowlwy and be careful.

Stimpy - good point about the rubber.

RCGBOB -Maybe if the clips aren't there it may be better to use little bolts to fix them, rather than risk the shatter!!

If you do use bolts be sure to loctite them in - we don't need any bolts inside that engine!!!

Tim

Update from the garage
 

Ok guys, there's good news and bad news.
It is an easier job than I thought. Uncliped the seat unit, - but did n't have to remove it, - carefullt balanced it 6 inches back. Got the wife to hold the tank clear whilst I unconnected the breather, 2 hoses and electrcal bit. Pulled the tank off. Pleasant surprise to find a big foam thingy in there, - careully pulled that off the trumpets, unscrewed them, got Henry hoover in there to get rid of all the bits that had fallen into the injectors. Got the old airbox off, easy, new one on, did not tighten up too much as new box has just carbon holes rather than sleeved with metal as the old one was. The rubber tank seal was glued around the forward edge, - but 10 mins with a stanley knife got it off and useable on the new. I did have the clips on the new airbox already. Bit of a fiddle to get the foam filter over the front trumpet, think I got it ok. Tank located over front sticky out bit, - going really well I am thinking, - call the wife to come hold the tank up whilst I re-connect the hoses, - she is not happy, as she is watching the Mummy Returns, - foget the greese on the petrol connectors, - prime the fuel system, - damn, - leaking from one side. 1 of the tiny O-rings has an edge missing. I was warned, even advised by a man that knows, Nelly, to buy new ones before I started the job, - I was even in a dealer's today.
So for the sake of 10p o-ring I miss the Surrey and South meeting tomorrow. :(

I will be in P&H tomorrow morning for a few o rings.

Putting the fuel connectors back, you have to push them up without releasing the little clip thing on the tank? I would imagine if you push that clip in, without the hose being connected fuel will just come rushing out?

Thanks everybody that has helped so far.

Very unlucky that it is a Bank Holiday tomorrow!

When you're pushing the fuel connectors (unions) back, you don't need to push the releases in,. you'll know if the pipes are connected corretly as these will click into place.

Did warn you about the grease though!!

Just make sure you grease the o-rings and that the connectors are lined up before you push them home.

Tim
;);)

all done
 

I really appreciate all the help here given by you all, - and thank you P&H for being open on a Sunday, -for those 16p little green o-rings. I joined the que of individuals holding their little plastic bags in front of the parts counter.
It is an easy job, - perhaps does need another person to just hold the back of the tank up 6 inches to get the hoses on and off, and anybody else reading this in future remember always grease your o-rings

It is good to do a job like this, - I have learnt a bit more about my bike, - and I discovered that I have an ITG foam filter that I did n't know i had.

Right then, - save for the carbon air-tubes and fit those next.

If you push the metal clips in on the tank side fuel does not come out. They purely retain the male fitting once pushed in to place. It is best to push these in as you fit the connector as it moves the metal edge away from the O-ring and reduces the chance of damge. Just sangging the metal clip can be enough to cause damage.

Ian
 

Were there any filters in the air tubes too?

'cause you won't need these?

Depending upon when the filter was fitted, you may want to look at oiling it!

Tim

thanks Tim, - no other filters in the tubes, just a pair of big bell mouths going into this big ITG foam box, - it was dirty and oily to touch, - did not feel wet oily but just a bit dirty oily, - I hoovered it to get rid of any dust/rubbish.
How do you know if it needs more oil?