Any one have the same experience of refitting the seat pan air box assembly Pro 03 after maintanence,I've read the other posts relateing to sealing the air box but putting it all back on to the carb is a right pain in the a**e.Any tips or mods would be welcome.

H

1- Put the airbox on & loosely fit the two righthand side bolts.

2- Put the carb into the airbox & tighten.

3- Pull the airbox/carb forward to fit onto the engine & tighten

4- Put left side airbox bolts in, loose fit.

5- Ensure carb connections are good at both end loosen & tighten as necessary.

6- Drop the tank in & then tighten up all the airbox bolts.

Edited October 7, 200421 yr by PERCE

It's easier than a Sherco, but I know what you mean.

I used to:

Wash the airbox out and leave on a radiator to dry out. Leave the rubber close to the radiator so it softens up.

Loosen the front jubilee clip to the manifold so the carb can move about a bit.

Quick waggle around as they meet up and it should go in nicely.

mines an 02. i've slightly elongated the bolt holes in the frame on the left and right side for the side panels.

I leeve the stupid clips off the frame, spray scilicone on air hose then wrestle the air box onto frame. When half in push carb into air box hose then tighten jubilee clip. Then guide carb into inlet hose, tighten jubilee clip. Fit speed clips to frame and tighten screws into both sides. Drop in tank and connect up.

It does get easier as the weeks go by

The reservoir was moved on the 04 models & it did make the job quite a bit easier.

The extension piece was not on my 02 or 03 bikes, the 03 had the flat slide carb on it, it was on my 04 bike. My 05 bike does not have one on. All my bikes have been 280cc.

I guessed I can't be the only one who has problems I'm going to take it to bits this afternoon on purpose to try out [must be nuts doing it on purpose].I'll ask the wife to see if the swear-o-meter registers from the garage later to see if it all works.Thanks again to all Workshop Yodas!

H

Took 15 mins reckon I could do it quicker next time and hardly any swearing just a gooo on my son !!! and JD.Even started and ran sweeter reckon I must have been getting air leaks before,thanks all again.

H

Bikespace if you read this will be in Oswestry for a couple of days at the end of the month is there any trialshops near worth a look hope to get to Telford for a look too.