Cutting Out The Air Surge Box???? - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 11 (permalink) Old 03-16-2019, 09:15 AM Thread Starter
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Cutting Out The Air Surge Box????

Greetings, I want to cut out the air surge box on my 1996 VN750. I have read that several you you have done this, but cannot find any details as to where you made the cuts. Is it best to cut across the middle or down the length??? Thanks, Lew
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post #2 of 11 (permalink) Old 03-16-2019, 11:30 AM
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Across the middle, but it still gives most everyone fits. Took mine out in one piece, but you have disconnect most of the wiring harness to do that.

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post #3 of 11 (permalink) Old 03-16-2019, 04:29 PM
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[IMG]DSCN0645 by Johnny Phaneros, on Flickr[/IMG]
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post #4 of 11 (permalink) Old 03-16-2019, 04:35 PM
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Drill a hole large enough for a hacksaw blade.
Wrap end of blade with masking tape and arrange the teeth so that they cut when you pull.
Or use an 'endless hacksaw'.
Or use a Sawzall with a long blade so as not to bang up the motor.

Place some wooden wedges above the airbox to stabilize it and keep it from moving up and down.

Once the box was cut, I wiggled and pulled the long part out toward the rear of the bike and I think I worked the small part out toward the left of the bike.

Cover your carb intakes. You don't want plastic shavings in there.

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Last edited by roadpouring; 03-18-2019 at 02:07 PM.
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post #5 of 11 (permalink) Old 03-17-2019, 12:54 PM
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hello i have 1986 vn 750 i rebuilt carbs went to start it and it ran but i noticed fuel coming out of air breathers any ideas the bike been sitting for 14 yrs
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post #6 of 11 (permalink) Old 03-17-2019, 01:59 PM
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Quote:
Originally Posted by brandonray34 View Post
hello i have 1986 vn 750 i rebuilt carbs went to start it and it ran but i noticed fuel coming out of air breathers any ideas the bike been sitting for 14 yrs

Stuck float.

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post #7 of 11 (permalink) Old 03-17-2019, 08:56 PM
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ok does the floats have to be adjusted bc i put new needles and everything in the carbs and thanks ill look at it tomorrow
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post #8 of 11 (permalink) Old 03-18-2019, 07:14 PM
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Originally Posted by brandonray34 View Post
ok does the floats have to be adjusted bc i put new needles and everything in the carbs and thanks ill look at it tomorrow

Probably don't need adjusted, unless they're actually too high and not stuck.

If stuck, usually some sharp whacks with a plastic screwdriver handle on the side of the carb can free it up.

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post #9 of 11 (permalink) Old 03-19-2019, 06:46 PM
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I made my cuts in the garage .
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post #10 of 11 (permalink) Old 03-23-2019, 11:03 AM
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Originally Posted by roadpouring View Post
[IMG]DSCN0645 by Johnny Phaneros, on Flickr[/IMG]
I did something very similar to that, but instead of cutting straight up, i cut forward towards the oblong holes where the air filter tubes went. I cut just a little bit in the upper front corners and the whole thing slid out the back. I think i made some parts more complicated than they needed to be, but it worked out in the end without damaging anything (except the surge tank)

Since the oblong hole collapses, it squished around the top of the front cylinder and i was able to pull the whole thing out in one piece without having to move a bunch of wires.
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1995 VN750
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