Tech Tip - Re-installing Air Box Intake Tubes

[Joe Hummer]

Had the air box out today to replace the vac lines (haven't done the desmog because I haven't had problems) and had a few issues getting the air box intake tubes back on.  After a little struggling, I figured out something that helped me get it back together...

The part I am talking about is part 6 on the diagram below:



The tubes will spin in the air box so you can turn them so that the back is in the front...that way...you can see if they are hung up.  Once you have the tube unstuck...you have a work partner push down on the tube you are trying to fit to help hold it in position.  A little WD40 does wonders also...slippery fish oil...you know...  To line them back up where they belong is pretty easy...there is a square notch on the tube that goes out when the tube is in the right position.  

Joe

[WamegoRob]

Cool, Joe, I hadn't thought of spinning them around.
I've only done the zip-tie method where you squeeze opposite tubes together so that they're pointing straight down, as in the below crude interpretation.
Zip-tie the three pairs, push it down through the frame then cut the zip ties.

[Joe Hummer]

Yeah Rob...my tip purposely did not cover re-installing the air box.  That thing is like a pissed off octopus who just lost 2 tentacles...(yep...that is the right word I meant to use...)  I figured the ones that have been brave enough to get that damn thing out have methods to get it back in...and I have seen tips on tying the tubes up.  I just hadn't seen anything on making sure the back of the tubes are on the carbs right.  Spinning them helped me see the back and...oh...sure enough...they were caught on the lip and doubled over.  Fixed that and they damn near fell into place...YEAH RIGHT...  

[olddog1946]

All the pics I have seen of the air box, it looked to me like all those tubes were glued in at the factory. Am I missing something?

[HayHauler]

olddog1946, I thought the same thing.  I asked many people and all of them said that they either twisted the tubes or just bent one side to install them and then bent the other side and forced the tubes down in between the frame.  All of them also said that they didn't re-seal these tubes to the air box.  With so many riding around with these tubes unsealed, I decided not to worry about it either.
I took the air box off 4 times before Inzane swapping carbs and it does get easier every time.  I guess you finally learn what to look for when putting them back on.

Hay 
Jimmyt

[saddlesore]

All the pics I have seen of the air box, it looked to me like all those tubes were glued in at the factory. Am I missing something?

When I was replacing vacuum lines I noticed the same thing.  I was taking care of any vacuum leaks so I figured I might as well seal the tubes while I was at it.
If it was sealed at the factory might as well do it.