Reply To: GTR125 Airbox

[Tom]

I seem to be writing Simon is right today alot, fit the funnels in air box first.

Then slide box in from left watching not to catch cables with box mounting screw hole tab.  Ensure the tab is clear of frame before lining up to carbs. Make sure all clamps to carb are loose enough and gently lean carbs to the left as you line up the funnels from the air box. Once the right hand side of funnels and carb are good then slowly straighten carbs, it should all go together as long as the funnel does not push into air box. It all feels like it is too tight to fit and leaning left with carbs allows airbox to wiggle backwards into position.  It is possible and you do get the knack of it.  I have had mine out 3 times now and can do it without cursing.

The new clamps make sure they are max 9mm width to fit properly. If you fit fit fatter ones they will seal but will pinch the rubber eventually causing damage.

Once fitted spray all funnel, manifold and vacuum connections with carb cleaner (flammable).  If revs increase then you have a leak.

Marcel is also right, be careful with those intake manifolds they are £300 for a used pair.  Mine had an old crackline split and I had to glue repair them, not ideal but it works.  I use the same glue I used as an engineer to glue drive belts and o-rings with, so if the manifolds do crap out on you it is possible to solve.

Good luck.