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.
We have lots of Court Jesters but now we have a Magician. Your work was amazing, persistant, just brilliant. Done the impossible. :hat: :hat:
Nice. Thanks for sharing. :salute: :clapping:
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.
@Eric GSX1400K3 QuoteSo 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!
Have stickied this - you never know who else might want to do this. Great job :onya:
How often does one need to remove the airbox?
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. :embarassed:
Quote from: VladTepes on Wednesday, 01 July 2020, 11:27 AM
How often does one need to remove the airbox?
Approximately never, I never have I know that.
Quote from: VladTepes on Wednesday, 01 July 2020, 11:27 AM
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
Quote from: GSX1400Convert on Wednesday, 01 July 2020, 02:37 PM
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. :embarassed:
thanks for this story
@GSX1400Convert I removed all the pop-rivets and plastic welded the whole thing now...