how do ya get the airbox out of an 09 d8?

[tahoermk]

Could someone let me know the proper way to remove the airbox from my 09 d8. I always just try to figure things out, but would rather not screw anything up, which usually happens. I am in the process of removing foam, getting the hood to fit, heat taping and sealing things up. I noticed the air horns( not sure what they are really called) right inside the airbox are really loose and rattle around. I hate rattles!! So, I want to remove the box and see what is up. The fit seems really tight when the strap is loose at the top, but don't see what I am missing. WHAT IS THE TRICK?
thanks for your help!
geoff

 

[CATKILLER]

there are hose clamps of some of the cfi sleds and you need to un plug the plug on the side of the air box and eather disconnect the fuel line or unbolt it from the box and other than that it should come rite out.

 

[tahoermk]

thanks I see them now! the hose clamps were turned so I couldn't see them. Anyone have a fix for the rattling air horns?

 

[AKSNOWRIDER]

thanks I see them now! the hose clamps were turned so I couldn't see them. Anyone have a fix for the rattling air horns?

just use silicone to hold them to the plates in the box..also seal up the box halfs at the joint..they suck all sorts of belt debris thru the crack(black ducttape works great)the 08 box is much easier to get in/out..it has a plate that clamps to the carbs then the airbox slides down onto the plate.......the 09 box is much tougher to get back in..I loosen the clamps holding the throttle bodies to the intakes and while sliding the box in I pull up tilting the throttle bodies up and forward so the box will slide back on....

 

[Ron]

Good post Mike, only one comment....gas disolves silicone so the blowback from carbs could eventually loosen any silicone around the air horns. Not as likely higher in the airbox but still possible.

 

[AKSNOWRIDER]

Good post Mike, only one comment....gas disolves silicone so the blowback from carbs could eventually loosen any silicone around the air horns. Not as likely higher in the airbox but still possible.

very true ron...I have never seen any fuel in the air box on mine..I was worried when I sealed the seams that fuel would get to them but its never been a problem....you riding your 09 still? any new mods?

 

[Ron]

very true ron...I have never seen any fuel in the air box on mine..I was worried when I sealed the seams that fuel would get to them but its never been a problem....you riding your 09 still? any new mods?

Yep, still riding the 09 but haven't been out yet this year. I have a project out of town that won't be done til mid December so just pining away as the rest of you tear up the snow. I'm not changing anything on my sled except will go with the Team Tied as soon as the R&D is done. Don't have any confidence that the recommended setup is even close, that would be a first.

 

[AKSNOWRIDER]

Yep, still riding the 09 but haven't been out yet this year. I have a project out of town that won't be done til mid December so just pining away as the rest of you tear up the snow. I'm not changing anything on my sled except will go with the Team Tied as soon as the R&D is done. Don't have any confidence that the recommended setup is even close, that would be a first.

lol..I havent rode either..sleds in peices changing over to the camo -x...was looking at the tied too but was worried about their angles..figured I would let others test first...

 

[AndrettiDog]

I haven't taken my 09 out yet, but if I remember right it helped to take off the seat and unbolt the tank on my 07. That just gave me a littel room to move things around in there. I didn't even undo the fuel line.

 

[Polar Express]

after you remove that top rubber strap, there is a hole in the side of the bulkhead perfectly located so you can stick a long bladed screwdriver (or nut driver) into, and get to the hose clamp on left side throttle body. The same driver will also access (no hole, just enough room) the right side.

I used a thin film of synthetic grease on the neck of the boots for re-install, and they just popped right on.

I agree with AK about sealing the joint. My box showed some signs of rubbing on the base, against the top of the tunnel. Something to keep an eye on.

Hope that helps!

PE

 

[tahoermk]

thanks

thanks for all the help!!! I will get after it ASAP and let ya know how it goes. Any other suggestions to sove the rattling air horns. How about some epoxy, hard as nails, jb weld or other fuel resistant glue?
geoff

 

[Trenchmaster]

I like to use black automotive Goop on my sled for sealing things up. It holds things together but remains flexible, did a repair on my 93 Cat EXT seat about 6 years ago and it's still holding strong!!

 

[AKSNOWRIDER]

thanks for all the help!!! I will get after it ASAP and let ya know how it goes. Any other suggestions to sove the rattling air horns. How about some epoxy, hard as nails, jb weld or other fuel resistant glue?
geoff

I wouldnt use anything that dries really hard..if it ever comes loose and goes thru the motor it will hurt it..the silicone I use is ultra black made by permatex..if you scuff up the plastic so it gets a good bite, then clean with brakleen before applying it and then let it dry completely it will be there forever....if it does come loose it wont hurt the motor ....