Airbox removal
1. Unlock seat.
2. See Figure 1-1. Remove airbox cover by turning bailhead fastener 1/4 turn counterclockwise (CCW). Pull airbox cover away from locating holes.
Figure 1-1. Airbox cover
3. See Figure 1-2. Remove IAT connector (1) by pushing down on bail wire to unlock. Airbox top is retained by eight clips (2), three per side, one at the rear and one in the front under the snorkel. Disconnect clips and remove airbox top.
Figure 1-2. Air Filter top: 1. IAT connector [89]; 2. Retaining clips
4. See Figure 1-3. Remove wing nut securing filter cap and air filter.
Figure 1-3. Air filter
5. See Figure 1-4. Disconnect breather hose (1). Slide o-ring (2) up the velocity stack body to access the three retaining fasteners. Remove the velocity stacks.
Figure 1-4. Velocity stacks: 1. Breather hose; 2. O-rings
6. Gently lift the air filter bottom. Front breather hose is a press-fit and will disconnect, rear breather has a worm clamp holding hose to air filter bottom. Loosen clamp and remove air filter bottom.
Caution! If airbox is not to be reinstalled immediately, cover throttle body intakes with tape to prevent contaminates/ objects from falling down the throttle bores. Do not use shop rags or objects that could damage the throttle body butterflies.
Figure 1-5. Airbox removed
Airbox installation
1. Remove tape from throttle body intakes.
2. See Figure 1-6. Inspect and replace bottom airbox gasket if damaged. Check gasket position on air filter bottom. Gasket is located by three alignment pins on mating surface.
Figure 1-6. Air filter gasket alignment pins (3)
3. Place air filter bottom over throttle body and attach rear breather hose with hose clamp.
4. Align air filter bottom with front breather hose and press firmly in position.
Note. Velocity stacks have a mark at the bottom flange between two of the fastener locations. Align the mark with the corresponding mark on the air filter bottom.
Figure 1-7. Velocity stack alignment marks
5. Align index marks and install velocity stacks, longest in front.Tighten fasteners to 6 Nm (53 in-lbs).
6. Slide о-rings down the velocity stack body until they contact the three fasteners.
Note. The о-rings retain the velocity stack fasteners when assembling airbox.
7. Attach the breather hose.
8. Place air filter element in air filter bottom.
9. Align air filter cap and fasten with wing nut. Turn wing nut 2.5 - 3 turns after contact.
10. Position air filter top over bottom section with snorkel between frame tubes at the steering neck.
11. Fasten clips along each side and clip at rear.
12. See Figure 1-8. Front clip under snorkel is attached to top section and must be fastened over the lip on the air filter bottom.
Figure 1-8. Front airbox clip
13. See Figure 1-2. Install IAT connector.
14. See Figure 1-9. Position the airbox cover with the locating pins (1) in the holes (2) on the frame tabs.
Figure 1-9. Airbox cover: 1. Locating pins; 2. Frame tab holes
15. See Figure 1-1. Turn bailhead fastener 1/4 turn clockwise.