Tech Tip: Airbox Installation - What Mr Suzuki should have done

[insane1400]

Its a shame Suzuki didnt put a bit more thought into the airbox and make it removable without having to remove the engine.
 Here is what I did to install an airbox into my bike.
 First I cut it into two pieces, then cut off the bulge where the PAIRS comes out of. The pairs hole had a piece plastic welded over the top.
 I then cut strips of PP plastic and wrapped it around the outside of the smaller section to create a "lip" to hold the larger piece in place. These were glued and riveted into place. 
 I had to remove the fuel injection to fit it in, but looking at it now its hard to tell its been done.

[grog]

We have lots of Court Jesters but now we have a Magician. Your work was amazing, persistant, just brilliant. Done the impossible. 

[Eric GSX1400K3]

Nice. Thanks for sharing.

So by cutting it in half i assume you also reduced the " length " of the airbox (front to rear distance?  As i understand its this length plus the PAIRS "hump" that makes  it a PITA to get out.

Ive thought about going the 4 pod filters route, but so far ive not needed to remove the throttle bodies or airbox, so I've  left it.

[insane1400]

@Eric GSX1400K3

So by cutting it in half i assume you also reduced the " length " of the airbox (front to rear distance?  As i understand its this length plus the PAIRS "hump" that makes  it a PITA to get out.

I didnt change any dimensions at all. In the first pic you can see the airbox with a white line around it, all I did was cut that line. I did sit looking at it for a while before deciding on where was the best to cut and how to rejoin it together... All up it only took about 5 hours to cut it, put the lip around and reinstall it.
 The trick with the two pieces of sheet metal to get the injection back in works a treat too!

[gsxbarmy]

Have stickied this - you never know who else might want to do this. Great job 

[VladTepes]

How often does one need to remove the airbox?

[GSX1400Convert]

All those rivets remind me of the aftermarket air filter I put on my 1964 Mini Cooper.

The air filter was held together with a screw on the inside of filter, the nut on the outside.

Driving to Griffith from Melbourne, just outside Jerilderri at night, it starts running on 3.

4 hours later, under the lights of the 24 hour Caltex servo, I finally got the head back on after taking it off to remove said screw from an inlet valve seat. 

[Hooli]

How often does one need to remove the airbox?

Approximately never, I never have I know that.

[gsxbarmy]

How often does one need to remove the airbox?

Generally never, but there are times when it would be useful without having to take your bike half to bits

[insane1400]

All those rivets remind me of the aftermarket air filter I put on my 1964 Mini Cooper.

The air filter was held together with a screw on the inside of filter, the nut on the outside.

Driving to Griffith from Melbourne, just outside Jerilderri at night, it starts running on 3.

4 hours later, under the lights of the 24 hour Caltex servo, I finally got the head back on after taking it off to remove said screw from an inlet valve seat. 

 thanks for this story @GSX1400Convert  I removed all the pop-rivets and plastic welded the whole thing now...