Front air box

[homieedoo1]

How do you remove/install the front air box on a 96 vs800 intruder

[sgtcall]

How do you remove/install the front air box on a 96 vs800 intruder

Welcome!
Here are a couple of things to check out.

POSTING PICTURES ON INTRUDERS ALERT
viewtopic.php?f=19&t=13992

INTRUDER MANUALS AND INFORMATION
viewtopic.php?f=19&t=14168

If the 800 is the same as the 1400 you have to pull the tank and front side covers, then move some wiring and lines out of the way, pull the couple of bolts that hold it in place and shimmy it out. Not really hard but kind of a PIA.

[YoutubeURL][/YoutubeURL]

[Herb]

with a lot of cussing and prying, after you remove the gas tank mount and the steering head covers.

[homieedoo1]

Ok after removing and pushing wiring and lines to the side wich way does the air box come out. Through the top of the frame or through the front by the radiator or do I remove the engine. I am stuck

[sgtcall]

Ok after removing and pushing wiring and lines to the side wich way does the air box come out. Through the top of the frame or through the front by the radiator or do I remove the engine. I am stuck

On my 1400 it would come out either from the top or, if I removed the oil cooler, from the front. Not sure if the 800 is the same but I am sure Herb can tell you.

[Herb]

Ok after removing and pushing wiring and lines to the side wich way does the air box come out. Through the top of the frame or through the front by the radiator or do I remove the engine. I am stuck

On my 1400 it would come out either from the top or, if I removed the oil cooler, from the front. Not sure if the 800 is the same but I am sure Herb can tell you.

I am not sure of the 800, I have only owned 1400s but considering that the 2 are pretty closely related I would imagine that they are close in difficuty. Considering that he is asking for help I would say it is really close.

Like I said. a lot of prying and cussing and mine came out from the top.

[Lechy]

The front air box on the 800's will only come out when the engine is removed from the frame. Unless you get the Dremmel out and butcher it.

[homieedoo1]

Thank you...glad someone knows how to do it. Instead of guessing

[homieedoo1]

Ok how about removing the sub frame on the right side. The arm that is removable by removing the four Allen bolts and sliding it in the front above the fan housing. I just got the engine back in and noticed the air box in the bottom of a box I kept the parts in I removed. I pulled the engine cause the engine was back firing through the tail pipe. I did a compression check and the front cylinder had 90 lbs, the rear had 115 lbs. I thought the exhaust valves were warped. So pulled the engine only to find both exhaust valves were way out of adjustment. No play what so ever and we're not closing. Reinstalled the engine and noticed the air box in the bottom of my parts box. Now hoping I don't have to pull the engine again. I am 71 years old.and It was a nightmare getting it back in

[sgtcall]

Thank you...glad someone knows how to do it. Instead of guessing

We guess because it keeps your thread moving in the algorithm giving you a better chance of being seen by someone that may know something better or have new information. Active threads are more likely to be noticed. But no issue can just let it fall into the nether regions of the board never to be seen again.

[Lechy]

You could use pods with socks. works well for me and no re-jet required:

[homieedoo1]

Now we're getting somewhere, could you tell me what company made ur pods. Are they 36mm and about the foam u have covering them. Did u have to adjust a/f screws ?

[Lechy]

The pods I got off E-Bay, You will need to measure your carbs as I can't remember, a vernier caliper comes in very handy if you are going to do your own wrenching. The foam is 1/2" filter foam from my local autostore. You will be best served to do a carb synch and AF adjustment as a final tune up.

Look here: viewtopic.php?f=32&t=4139

[homieedoo1]

On the front carb, won't the pod hit the gas tank?

[Lechy]

It's a bit of a snug fit in the tunnel but I had no problems.

[homieedoo1]

Could I ask you what did you do with the cables that were attached to the front air box?

[Lechy]

Cable ties and a little rearranging. I also fitted a new spedo/tach assembly for these cables I used electrical heat shrink tube. The throttle cable splitter is still hanging but making a mounting bracket is not a big job.

[homieedoo1]

Thank You for ur help and time. I ordered e-bay pods(50mm). I removed the right sub.frame and still couldn't squeeze the front filter housing home. I'm not taking that engine out again. The situation made the decision for me...Thanks Again Lechy

[Lechy]

Don't forget to cover the pods with filter foam, this is to emulate the drag caused by the airboxes and OEM filters which cause a slight negative pressure in the venturi necessary for the correct operation of CV carbs.
Hope it works out for you.

[homieedoo1]

Will due...Thanks