Bonneville America Forums Forums Technical Forums Performance Mods Air box removal questions

I have checked the "Ghetto freak" in the archives.
I have the air box backed off about 4" and it is binding.
The author discribes removing "5 bolts holding the (battery) carrier in place (3 hex head and two conventional)"
I found the two conventional holding the ignition switch although the bottom one is hard to get at. I removed 2 Hex from the tray bottom of the carrier. Where is the third Hex bolt?
I take it you destroy the fuse box studs in the process or removing them? Just pry them loose?
Once the rear shocks are removed the axle nuts sit on the exhaust pipe limiting the clearance to pull the air box out.
What am I missing here?

You're going to have to pull the rear peg hanger bolt that holds the exhaust pipe so the axle can clear the silencer. Then you should be able to wiggle the air box clear. Also, if you pry very carefully at the fuse box "studs" you might be able to save them. Don't know about the "third" bolt issue.

I also unbolted the top of my air box from the bottom to make it easier to get out.

Hi Stephen.

Just went through that myself. My son and I did our pair of 06 BAs. The air box is a tricky thing, and seems to want to wiggle out only one way. It worked best for us to pull the pipes, and then jack the stand up until the swing arm is just shy from touching the rectifier(?) on the back of the frame under the swing arm.

The back end of the box needs to drop down, and then out at a downward angle. Watch the two tabs on the right side - one of the left top cover screws will want to push it to the side and break them off. When it's mostly out it can then be turned counter clockwise a quarter turn, and then slid out along between the tire and fender out the back. The bottom of the box will follow the profile of the tire.

I had the air box in and out quite a few times to think and measure the cuts I wanted. The first time you do it it'll be a two or three beer job, after that it's in and out between swigs!!

We didn't have to take the fuse box off the battery tray. Just the two bolts at the bottom of the tray, and the one lower down that goes into the side of the frame. The whole affair can then be moved to the side enough to slinky the box out.

Hope this helps

A dremel and cutoff wheel makes quick work of it too

I took my rear fender off to pull the air box. Made my life much easier.

before i permanently removed mine, i just cut the box back while it was on the bike to make room for the pods. Taking it out was too much work for me.

When i decided to permanently remove it i just cut it into pieces with a saw zaw..haha

Thanks alot guys. I will give it a try this weekend.
Now I noticed in the archives some points to the negative on removal. Performance in cross winds and the snorkle really not be a restrictor but an air ram. Is there still consensus that removing all is the best way to go. Snorkle,two pipes in the air box and reducing or eliminating the air dam? I am planing to cut out the bottom of the box at the air filter also.

word of advice -- especially on the left pod, take off LOTS of material on the airbox. the way it's set up, there's less wiggle room on the left side of the bike than the right, and so you need to clear out more airbox to make room. once you're done, the airbox is ****** near useless anyway, so who cares?

This will, mind you, probably prevent you from being able to put on the little doohickey that sits in front of the ignition and above the battery. it doesn't look too bad -- some guys fab up a little cover 'cause it bugs them -- jsut be aware that this is a potential side effect.

My bikes' been like this for over a year and Im' pleased as punch. Justg make sure you rejet at the same time!

--Jaeger

yeah it doesnt look bad at all without that cover that goes on top of the battery. In fact it was missing when i bought my bike used, and it never stood out to me that anything was missing at all. Then i found this website and seen pics of other bikes, like "whats that plastic thing on the battery?"

I did get the box out thank to your help. I did take the fender and shocks off and dropped the rear wheel. The wheel was hung up on the exhaust but they spread horizontally very easily allowing the wheel to fall. I did find something unusual. One of the 2 drain hoses had broken off.
Inside of it was a small rubber cap about the size and look of the one you get with the AI kit. It had to have been put there on purpose effectively making the hose useless. Does any know if it has a purpose? Also I had 2 rubber mounts fall and did not notice were they came from. I take it that they are associated with the shocks? Also a small, Im not sure what its called but it look like a small washer with a ridge around the hole as if it insets into something?

The small washer with the ridge around it was probably underneath one of the screws/bolts that secure the airbox to the inside of the rear fender.
The rubber mounts could possibly be from underneath the rear footpeg/exhaust mounts. Could be shocks too.

might be the washer for the wire hose retainer under the battery box just aft of the primary.

I have never had a negative performance issue with my pods. Ridden in driving rain, high cross winds, and any other weather condition you can think of. My bike never skipped a beat.