How to remove and install airbox easily - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 8 (permalink) Old 03-31-2016, 09:24 PM Thread Starter
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How to remove and install airbox easily

I needed to remove and reinstall my airbox when I did an engine installation on my project build the other day. I searched for the way to remove it only to find the proper way is to drop the engine. There was many suggestions in search such as hacksawing it in half, C4 explosives, and so on, but no actual real way to do it in a way that it came out and went back in without heavy damage and modification.

One poster suggested that removing all the electrical around it would provide enough room, but that is not the case as that is not the reason it will not come out. The issue is that the part of the airbox in the front that dips down causes it to catch on the head when the top of the airbox is against the frame and cannot be forced to go past it in ANY WAY WHATSOEVER. The plastic is very strong and does not bend.

Follow these pics to make a small modification that will allow you to safely and easily remove or install the airbox with ease and no resistance whatsoever. It will literally slide in and out like butter. When you are done, you may either use duct tape, glue, or anything else you wish to seal the seam. You are not leaving a huge gash or any major structural degradation with this mod, you are only making a very tiny seam. Nobody will ever know you did anything at all and it will be good as new.
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post #2 of 8 (permalink) Old 03-31-2016, 09:25 PM Thread Starter
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post #3 of 8 (permalink) Old 03-31-2016, 09:27 PM
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Speaking from experience, you can definitely get the surge tank out with no modifications by getting the wiring out of the way.
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post #4 of 8 (permalink) Old 03-31-2016, 09:42 PM Thread Starter
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I can say out of the 20 people I've asked only 2 have been able to do it, so while it's possible, it's not likely for the majority therefore a non destructive option is needed.


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post #5 of 8 (permalink) Old 03-31-2016, 09:57 PM
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Sounds like we need someone to document the process with pictures. I don't remember it even being all that difficult, honestly.
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post #6 of 8 (permalink) Old 03-31-2016, 10:36 PM
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Popped mine out in one piece after taking the harness out of the frame. Might have also unbolted the brackets that hold the elec. plugs behind the neck.

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post #7 of 8 (permalink) Old 03-31-2016, 11:16 PM
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Popped mine out in six pieces with help of a jigsaw and a large prybar
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post #8 of 8 (permalink) Old 04-01-2016, 08:36 AM
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Quote:
Originally Posted by OleDirtyDoc View Post
Popped mine out in six pieces with help of a jigsaw and a large prybar
aww, I missed all the fun, mine came out in 2 pieces..

btw, now that you have it out, when you put it back in, how are you going to seal the slice you made in the front of the surge tank? you are going to let in a lot of dirty crappy air if you dont seal it somehow. keep in mind, whatever method you use, needs to be fuel/oil proof/safe.. even tho the thing is meant for AIR, there are oil and fuel fumes that get inside it.

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