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Offline lemuriano

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Air filter box removal
« on: November 10, 2015, 04:26:29 pm »
I'm trying to get to the cam cover in order to change the spark plugs, but don't know how to remove the air filter box. Faring off, fuel tank off, next is the air filter box.

As a side note; I was surprise to see the air filter on this condition after 27,000 miles

Can someone be kind enough and  :440: point me in the right direction?


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Online janfmiller

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Re: Air filter box removal
« Reply #1 on: November 10, 2015, 04:38:11 pm »
I just did the 20K inspection and adjusted the valves.   I took a ton of pictures, and intend to post a How-To shortly.

But basically, disconnect the 2 hoses, the line out of the clip on the right side, and 3 wiring connectors, then the two mounting screws on the back noting the orientation of the clip attached to them, the front screw, and then pull straight up.

The rubber spigots are merely a slip-fit over the throttle body intakes and pull right off....

I would be interested to see if your airbox also has four small holes on the bottom.   

Be really careful when you put it back on, ensure that all 3 spigots are fully engaged.

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Offline atrophy

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Re: Air filter box removal
« Reply #2 on: November 10, 2015, 04:54:54 pm »
Janfmiller, looking forward to your post.

I have never done this on a bike with shims.

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Offline lemuriano

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Re: Air filter box removal
« Reply #3 on: November 10, 2015, 05:40:09 pm »
*Originally Posted by janfmiller [+]
I would be interested to see if your airbox also has four small holes on the bottom. 

Air box out. Really appreciated your help.  :047:
In regards to the holes, my air box also have then.
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Online janfmiller

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Re: Air filter box removal
« Reply #4 on: November 10, 2015, 05:49:14 pm »
Good and bad news, I worry about the presence of those dirty air inlets....

Valves are pretty straightforward, do you have a Shop Manual???   

One thing I did was zip-tie the cam chain to the cam sprockets before removing the cam chain tensioner. 

Be sure and put the lock pin ( a long 6mm bolt works fine ) in the crankshaft through the cases when the two marks on the camshafts are pointing toward each other ( and aligned with the head's gasket surface ) before removing the cams and you'll be golden.   

There is plenty of room to remove one cam at a time to remove the valve buckets.   I'd cup a hand underneath the bucket as soon as it comes free ( I used a magnet on a stick to remove them ) in case the shim drops out. 

All mine were stuck to the bottom of the bucket, but they are installed in a recess on top of the valve spring retainer.

Be sure and follow the loosening and tightening procedures and use a torque wrench ( a topic beaten to death lately in these pages !! )...

I got a 9.48mm Hot Cams shim kit from Amazon for about $60, 3 of each size.   Of course I needed FOUR of one, but was able to re-use one of the shims I removed to get the valve in-range.  I prefer to set as close to the higher tolerance as possible.  Tappy == Happy...

Good luck!
1977 Suzuki TS-185
1974 Kawasaki Z-1 903
2013 Triumph Trophy SE
2017 Honda Africa Twin NON-DTC
2021 Honda Africa Twin Adventure Sports ES ( in the mail )...