GTR125 Airbox
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After a bit of assistance. I took the airbox off the carbs by brute force as the screws were rusty and rounded off (should have drilled them but i was too impatient 😕) how do you refit it onto the carbs? Do you put the seals onto the carb them push the airbox on? As there doesn’t seem enough room to fit to airbox, push on then secure. Or am i being thick? Any help is greatly appreciated.
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Can you get some pictures of your situation if possible, so we can see where you are stuck exactly , as it should go in the same way you took it out.
However, i would caution not to stress the manifolds, korea doesn’t make em any more and be ready to fork out ££££££s just to even get a decent half -cracked up one .
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I pulled the airbox off the carbs (breaking the airbox at the retaining screws) so it came off with the 2 small rubber sealing rings still attached to the airbox not the carbs. So do i attach the seals to the top of the carbs and secure with the clip attached then just push the airbox onto the carb with a bit of lube and the seals should pop in?
Or pop the seals into the airbox then push it all onto the carbs and tighten the clip up?
I’m probably making this more hard work that it needs to be 😖
Can you get some pictures of your situation if possible, so we can see where you are stuck exactly , as it should go in the same way you took it out. However, i would caution not to stress the manifolds, korea doesn’t make em any more and be ready to fork out ££££££s just to even get a decent half -cracked up one .
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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.
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