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Buell Forum » XBoard » Sanity Check: Should the factory inner airbox touch the outer airbox cover? « Previous Next »

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Badbueller
Posted on Monday, December 13, 2021 - 09:30 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I recently removed an open airbox kit that came on my 2005 XB9SX and replaced it with the factory inner airbox lid from a 2008 XB12. It installed with no issue; but when I went to install the outer airbox cover the mesh vent is contacting the front of the inner cover. I can get the front holes to line up by pushing down on the cover, but it just didn't seem right. Is this normal? There really isn't too much to this assembly, so I am not sure what I could be doing wrong.
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1_mike
Posted on Thursday, December 16, 2021 - 05:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

On one hand, on my 2005 XB, my outer cover does not have the screen in front... On the other hand, the actual air box cover has rub (white) marks on it where the "body" cover rubs on it, apparently regularly in a couple of locations.

So with that info from my XB, I'd say yes, it is normal.

Mike
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Badbueller
Posted on Thursday, December 16, 2021 - 08:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Mike, thanks so much for checking. Iím also not sure if the vent changes the front or not. Mine has a lot of interference; I would have to really flex the plastic for it to line up with the front holes. I attempted it and was afraid that I would damage the tapped holes. I will shrink some photos tomorrow, so maybe you can see what I may be missing. The black front ring around the gas cap is also pushed out.
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Badbueller
Posted on Friday, December 17, 2021 - 02:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Here are a few photos showing the contact at the vent, the misalignment of the front holes and the mounting of the inner cover. Anyone see any cause of my issue?









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34nineteen
Posted on Monday, December 20, 2021 - 02:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My airbox cover rubs on the front left center portion, right below and to the left of the fuel cap.

And BTW, yours is on backwards.
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Panhead_dan
Posted on Tuesday, December 21, 2021 - 11:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

"Anyone see any cause of my issue?"

In the last picture, it looks like the upper and lower halves of the air box are not mated correctly. Th corner closest to the camera shows a big gap between the halves.
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Badbueller
Posted on Tuesday, December 21, 2021 - 11:27 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Panhead_Dan, I saw that as well. For some reason at the back right corner and front right corner there is a about a 3mm gap no matter how I adjust it. The K&N filter is pretty tall it seems and the little clasps are too far apart. There does not seem to be a gap across the front behind the gas cap though where the interference is happening.
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Zacks
Posted on Tuesday, December 21, 2021 - 02:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Have you tried it with out the air filter installed to see if it's better?
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Skipbarberman
Posted on Tuesday, December 21, 2021 - 04:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

As Zacks stated, try it without the filter. I had the same issue at one point, and found that I had to grease the K&N and force it down over the bottom plate support to get the top to close/line up. Also, there is a few mm in each of the bottom plate mounting holes for the shouldered bolts. back everything off, and slide as far back as you can, then tighten EVENLY and PROGRESSIVELY around the base plate. If you don't, it'll pull and twist, creating cascading problems. Remember, it starts with the baseplate mounting to the top of the engine and finishes with the airbox cover mounting to tabs on the frame. It's all gotta fit together correctly to maintain the correct overall height. Hope this helps. - Sean



(Message edited by skipbarberman on December 21, 2021)

(Message edited by skipbarberman on December 21, 2021)
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Badbueller
Posted on Tuesday, December 21, 2021 - 09:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Zacks,
Thatís a good idea. I ended up temporarily Reinstalling my open airbox kit because Iím going for a ride tomorrow weather permitting. I will give that a try soon. I know a lot of people have K&N filters and itís a stock airbox; itís strange that itís such a tight fit.

Sean,
Those are great points and I will definitely try that. Thanks a lot for the step by step. When I get back to swapping it I will do exactly what you said. Have a merry Christmas! I hope Rock Hill is treating you well!

(Message edited by Badbueller on December 22, 2021)
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34nineteen
Posted on Thursday, January 06, 2022 - 10:18 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Damn you Badbueller! Now I can't unsee it on my bike.

I may get some clay later this week and see what the clearance/interference really looks like.
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Badbueller
Posted on Thursday, January 06, 2022 - 04:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

@34nineteen - Sorry about that. I'm pretty good at complicating simple processes and creating new problems that you never knew that you had!
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