Left side view of bike showing air filter housing
between rear of gas tank and above electric starter motor. |
It's a good idea to switch of the master battery
switch or disconnect the battery since you are working near the
battery terminal and alternator connections. |
Remove the side cover (if applicable) for better
access to filter housing. |
A nice wide open view with the cover removed. |
Use a screwdriver to pop off... |
...the breather tube from the air filter housing. |
Use a screwdriver to loosen the upper... |
...and lower branch tubing clamps on both the left
and right side of filter housing. |
Remove the branch tube assemblies; clean any oil/dirt
build up from the inside with a rag and set the branch tubes aside. |
Use the 13mm wrench to remove the nut/washer (bright
nut behind clutch cable screw)on the bottom right side of filter
housing. This nut also holds the bracket for the forward clutch
adjust screw. Do not remove the clutch adjust
nut or screw! |
Next, remove the upper retaining bolt for the
electric starter. |
Use a long 8mm Allen wrench for this. I like the type
with the off-angle ball on the end as it is easier to position into
place. |
Move the kick starter lever down and out of the way.
Use a bungee cord or your foot to hold it down. |
You can use a 3/8th's ratchet extension as a cheater
bar to break the starter bolt loose. |
The filter housing can now be eased out the left side
of the motorcycle frame. |
Set the housing upside down and use a 10mm wrench to
loosen the two nuts on the bottom of the housing. You may need
another 10mm wrench to hold the bolt head on the top cover. |
Flip the housing right side up and lift the cover
off. There are two tube spacers that may fall free so be watchful.
You can now see the air filter element. |
In the newer housings the filter element is held in
place by a plate and two bolts that extend up through the top cover
for the air intake. |
Again, use a/the 10mm wrench/s to remove the two nuts
securing the plate to the filter element. |
The element is now free to remove and clean/replace.
I use a K&N #E-2470 element and use the K&N cleaning kit as per the
instructions in the box. Wipe any excess oil/dirt from the housing
before assembling. |
A half ass view of the top cover assembly. There are
4 tube spacers; the long one inside were the element sits and the
two short ones under the cap to the air intake. |
There is a rubber seal that goes under the lid. Make
sure the hole in the seal aligns with the hole in the top cover.
This is especially true of the early (pre-2003) housing as the seal
can be put in "upside down" covering the intake hole in the top
cover. The engine does not like this and will run like shit until
you figure out your mistake. |
Make sure the filter
element is dry before reassembling the housing.
Reinstall the air filter housing using the reverse
sequence for removal.
There were two types of "blue" OEM filter
elements. The earlier had a gauze element and could be cleaned and
re-used. The later used a paper element and could not be re-used. It
would also choke the engine if it got wet while riding or washing
the bike.
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If you have not
already, I highly recommend you purchase the K&N element mentioned
above. It is made better, breathes easier, handles water ingestion
much better and with little care will last many years. |
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