Wednesday, June 19, 2013

Triumph Bonneville Mods for Airbox Removal

The Stock Airbox
Unfortunately the airbox can't be done away with completely because it holds the battery, acts as part of the rear fender and is a mounting point for various parts and systems. While the airbox removal kits offer a machined replacement to hold the battery and relocate mount points, we can do the same thing for much cheaper by chopping up the stock airbox. When cutting we have to carefully work around important features removing only as much as we need to fit the new air filters. I prefer not to destroy the stock parts on my bike so I ordered a spare airbox to tear up from a salvage parts dealer.
The battery box supplied by the kits provide a very minimalist replacement but as you're not using the space under the seat for anything else you may as well get creative with it. I decided to turn the air filter into a tool stash by tearing the pleats out with pliers. I clipped off the top and fitted some 1/4" vinyl tubing around the rim to keep it snug in its nook.






To make room for the new air filters, I had to cut from the front of the battery compartment, down and around the old-air-filter-turned-tool-kit. I used an angle grinder to cut most of the material off and then a hacksaw for the details. Both worked through the soft plastic like warm butter.
If you are planning to use the old air filter, make sure not to cut off the splines that hold it in place!

On the right side of the airbox are the rear brake reservoir and fuse box mounted on a metal bracket along with the carb heater relay press fit beneath the fuses. On the left side are two relay boxes and the starter solenoid. To make room for the new filters, the fuses, carb heater relay and starter solenoid all have to find new homes on the airbox. While deciding how best to go about doing this, my girlfriend hit upon the idea of using heavy duty velcro. This is great because it makes getting around the airbox for other maintenance much easier. Since the rubber mounts on my relays were toast, I decided to velcro those as well. The starter solenoid was relocated right next to the relays, while the fuses and carb heater relay moved to the front-facing side of the airbox.

A quick note about removing/installing the stock airbox: although I saw some posts online in which folks claimed to remove the stock airbox without removing the rear wheel, I was not able to do this. In the end I removed both springs, the rear fender, the left muffler (to access the axle bolt) and the rear tire. The extra space makes it much easier to fit the airbox and associated wires, hoses, etc. comfortably.

And that's all there is to it. Be sure to follow the manual closely when reassembling the rear of the bike. Don't forget to check the rear wheel alignment and tension the chain correctly before tightening the axle nut and make sure that everything is snug before calling it a day.

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