90's NH airbox removal

[capz]

The airbox to carburetor tubes on my NH are shot. I can't get the clamps to stay on. So I ordered the new tubes but I just can't get the airbox out. I tried right and left of the frame. The only way I can see it coming out is straight back. But I really don't want to take off the rear tire, fender, lights etc.....
I'm hoping someone who has done this has better news for me.

[tomb raider]

Gota do it, same on there atv's.. Gives a chance to clean well.

[drdubb]

Why are you removing box?

[capz]

The clamps just don't fit around the carbs right, no matter what I do to hold them close to the carb and tighten, they always slip off.. When I got the bike the two middle ones were hanging off, not even around the carb body. Also there's gasket sealant around where the boots meet the box that's cracking (not sure if the sealant is from the factory or PO). I figure an airtight seal at these boots isn't as important as the engine intake boots but I'd still like to get it right. Plus I already took one off trying to get the box out and it's seemingly impossible to get it back on with it on the bike. Any tricks to getting these things on?

[drdubb]

The tricks are: some armor all on the boots to slip on. Use a hair dryer to make supple. I use ratchet straps to pull box and boots up to the carbs.  Dental pics are useful. You can get automotive versions at Sears. The sealant around the the boots is factory. I've not found a suitable compound, but I'm looking. I think 3m 5200 would work well, but I need to get it in black. The boots will come off with a little twist and rotation down. Getting them back on is another matter, although I've done it on a 650. When you get your new boots, you will see how it all works.

I wouldn't take the boots off of the airbox unless there is not other way. Use some of the tricks above. The hair dryer is indispensable. Don't tighten the clamps too much.


The photo shows the boot hooked into the box, although its not quite all the way in. There is a lip that catches around the edge of the opening. The sealant makes it airtight.

[capz]

Good tip with the hairdryer. I was thinking of dipping the ends in hot water. I MIGHT be able to get them on with the airbox on the bike but I won't be able to put sealant all the way around. And I'd like to do it right so it looks like I'm taking the long route, which would be sweet if I was riding in June.

[drdubb]

All of that can be very frustrating. New boots would make the job easier. I've got two bikes, a 95-750 and an 83 650. The 95 is easy to do, the 83 is tough b/c the boots are so tough. I actually got a box and boots off ebay for the 650 and the next time I pull the carbs, I plan to pull the old box and do the job like you are describing. Right now, I just want to ride the darn thing.

[capz]

Well I got one of them on using very hot water. The other one is backordered. I'll use the hairdryer method for that one. You're right about the new boots being easier, they're MUCH softer. Anyone reading this, don't even bother getting used boots or trying to put old ones back on. It still took me over an hour and about 20 curses. Oh and one black thumb from slippage. You just have to work it over the lip a little at a time from inside the airbox. I used a dull flathead screwdriver and pushed every which way.
I also found my air filter filled to the brim with acorns. Must have been a chipmunk or a small squirrel. So the little !?#$ lost his stash.
Thanks for the help doc!