2016-09-21 Gen 2 2006 Airbox Repair

[dcarver]

2016-09-21 AirboxRepair




published by dcarver on Sun, 11/20/2016 - 15:44


Forums:
KrZy8




So then, at Rueben Run 5, KrZy8's starter motor required replacement. Fortunately for me, good bud Ray was there to offer a lift and advice and hands to pull the tired motor and replace it. While there, we discovered the air box intake runner tubes were not the same length. RR here.

So we did our best to get things sealed up. But, after the air box re-installation, a strange honking noise, audible even through ear buds and XM radio. But only at one RPM band. Thinking on it, decided to ride it home, approx 900 miles, worry about it later.

Back home, pulled the box. Note the shape of runner 2 from left side.



More shots, no words needed.



Tube pulled out of box.



Yamaha used a pretty sticky adhesive, flexible, as it should be.



Orangie supervisors from Naomi, BeemerDon's 2013 FJR.



And leaves his paw prints as evidence.



Disassembled.



Reassembled.





Molly says, 'Where's that damn cat?'



The alignment is better, but not good.



Used grease to lube the runners. A mistake. To slippery. Will not stay on the FI body housing.



Greased the TB housing too.



When only two hands are available, make do with make with.



After 3 attempts and failures, (definition of insanity?) Removed grease, used Citrix cleaner as lube. It dries quickly, leaving adequate friction to keep the boots mounted while you get to the clamps.



Done. And sealed.



This actually worked. But I bought a beautiful new airbox, complete, for 20 dollars from eBay. And the alignment is much better. Next time in, this box will be removed and hit the recycling can.

Hope this helps someone in the future.

 

[FJRay]

How many bikes are you going to have in pieces at once. You're gonna confuse yourself and Molly dog won't help you out.

 

[escapefjrtist]

Nicely detailed dc...not that I ever plan on performing airbox repair!

--G

 

[Fred W]

I found the same difficulty in getting those snorkel tubes on the TBs when I removed and cleaned the TBs at ~90 k miles on the 1st Gen. Mine had not separated from the air box at all though, just that they are difficult to get on. I used a small smear (much less than you did) of silicone (dielectric) grease. A little grease goes a long way. And you don't want to ingest any of that if you are still using your O2 sensor (I was not). It still took a great deal of prodding to get it on there and clamped securely.

With that much dust and dirt on the "clean" side of your air box you probably should keep an eye on the engine compression for a while. Jus' sayin'...