Dear god how to get airbox on

[Stevelmk]

Hey lads I have up to date tried for 12- 15 hrs to get airbox back into my fj11 I have the Chinese pattern pods in at moment don't like them and can't afford the tuning and dtnky costs over here .

I have dropped subframe got carbs in loose and the airbox just won't go in if one end goes on the other side pops off. Tried again two days ago and tried for a solid 5 hours to no avail I had all the little arrows on side of box in middle

[Dieselman7.3]

Have you tried spraying pb blaster or oil of some kind to lube them up?

[Troyskie]

G'day Steve,

I believe it is the sequence of installation that might be giving you grief.

Step one remove the two top subframe bolts. Make sure you have a block of wood, wadded rags, etc. to support the subframe at the height you want (the subframe can sag onto the rear wheel and scratch the subframe lower front mounting point tubes against the footpeg bracket).

Step two, loosen, but don't remove the two bottom subframe bolts (the ones that go through the footpeg bracket).

Step three, (carbies floating free with cables attached) push the carbies into the airbox, check seating, and tighten the ring thingy screws to hold them together nicely. You'll have plenty of play to get it right. NOTE, as you've spent hours on this already, try removing the subframe enough to completely remove the airbox and 'bench fit' the carbies to the airbox. You'll find they need to seat at the bottom first. Do it a few times to get a 'feel' for how they want to fit on. Also, use rubber grease, not too much, but use some on both the airbox and the inlet manifolds. Also, regarding the little arrows, they have a corresponding mark to line them up with on the airbox.

Step four, set the height of the subframe so you get a good angle to push the carbie/airbox set back into the inlet manifolds (remember lower bolts in but loose). Although stiff, it should sort of snap into place. I'm not very strong and I had to lever them on from either side. It will be harder if the manifolds are old and hard. A heat gun on them might help, but I've not used that yet. Don't forget a little rubber grease.

Step five, curse me for giving you instructions that don't work for you, or if it works, don't forget to tighten all the manifold screws.

Step six, beer helps with either celebration or commiseration.
drinks
Troy

[oldktmdude]

   Skip everything Troy said and throw it in the nearest bin and fit Unipods! 
   

[Sparky84]

   Skip everything Troy said and throw it in the nearest bin and fit Unipods! 
   

Everything! 
Even "Step Six"! 

R U OK Pete?

[roverfj1200]

   Skip everything Troy said and throw it in the nearest bin and fit Unipods! 
   

Everything! 
Even "Step Six"! 

R U OK Pete?

[oldktmdude]

   Sorry, I should have said, PROCEED DIRECTLY TO STEP 6. 
Old age, you gotta love it!

[Stevelmk]

G'day Steve,

I believe it is the sequence of installation that might be giving you grief.

Step one remove the two top subframe bolts. Make sure you have a block of wood, wadded rags, etc. to support the subframe at the height you want (the subframe can sag onto the rear wheel and scratch the subframe lower front mounting point tubes against the footpeg bracket).

Step two, loosen, but don't remove the two bottom subframe bolts (the ones that go through the footpeg bracket).

Step three, (carbies floating free with cables attached) push the carbies into the airbox, check seating, and tighten the ring thingy screws to hold them together nicely. You'll have plenty of play to get it right. NOTE, as you've spent hours on this already, try removing the subframe enough to completely remove the airbox and 'bench fit' the carbies to the airbox. You'll find they need to seat at the bottom first. Do it a few times to get a 'feel' for how they want to fit on. Also, use rubber grease, not too much, but use some on both the airbox and the inlet manifolds. Also, regarding the little arrows, they have a corresponding mark to line them up with on the airbox.

Step four, set the height of the subframe so you get a good angle to push the carbie/airbox set back into the inlet manifolds (remember lower bolts in but loose). Although stiff, it should sort of snap into place. I'm not very strong and I had to lever them on from either side. It will be harder if the manifolds are old and hard. A heat gun on them might help, but I've not used that yet. Don't forget a little rubber grease.

Step five, curse me for giving you instructions that don't work for you, or if it works, don't forget to tighten all the manifold screws.

Step six, beer helps with either celebration or commiseration.
drinks
Troy

Hey Troy quiet detailed thank you I will follow steps and give it a go over the weekend and hopefully get it all together

[Troyskie]

   Sorry, I should have said, PROCEED DIRECTLY TO STEP 6. 
Old age, you gotta love it!

He he he, I'm at step 6 now....

[Pat Conlon]

Put the beer away laddies, you're not done....

How about connecting the crankcase vent hose to the bottom of the air box?  That's a pisser....

[Troyskie]

Put the beer away laddies, you're not done....

How about connecting the crankcase vent hose to the bottom of the air box?  That's a pisser....

Good point Pat! That would be step 6.

I'll get to the new step 7 later