VT500c air box not lining up...

[CiDirkona]

Hello all,

I have a 1983 VT500c. I had a fuel line fail on me and pulled the tank and air box to get to the line. I noticed when removing the air box that the rubber tube that goes from the right carb input to the air box wasn't attached to the airbox properly -- leaking unfiltered air in around it.

Afterwards though, I couldn't get the airbox back on both carbs without the rubber tube popping back off the air box. With the rubber tube in the airbox properly, it didn't line up to the right side carb correctly.

Is there something I should be doing? I tried a forum search but didn't come up with anything -- if I missed something somewhere, feel free to point me in the right direction.

Thanks in advance!

[adventurer2112]

HI,
85 VT500 I used my friends hair dryer to warm up the airbox and the carb boots, also sprayed WD- 40 in to the boots, made it a lot easier, still a pia tho.
Tickled pink to be riding again
Jack

[CiDirkona]

Hey, that's a great idea with the hair dryer... -- it could move it up just a bit in order to make it line up again.

I was also thinking of putting a dab or two of rubber or sealant to help hold it in the groove on the airbox while I slip the airbox down and over the carb input...

[still_bluenoser]

dish detergent on the rubbers.

[Misfit]

I use silicone spray, a lot of cursing, a lot trials & errors, and a lot of beer afterwards. Probably the worst thing to deal with in these old VT's!

What I usually have to do is loosen the carbs from the manifold boots, attach 'em to the air-intake, and then realign & tighten the carbs back onto the manifold.

Good luck. It's a real PITA!

[CiDirkona]

Thanks for the tips -- I didn't even think of loosening up the carbs to help them line up.

I'm almost tempted to buy some pod K&N filters to stick on there and rid the entire airbox altogether. I'm not sure if I'd have to rejet at that point or no. At this point I'm running no air filter at all with the airbox leaking as it is!

[Tobias]

I also have an '83 VT500. My air box goes on fine. I struggled with it a few times and now I get it on easily and quickly with no special tools or anything weird.

Put the two rubber hoses that go between the carbs and the air box on first and tighten the clamps.

Don't forget to get your other 2 clamps on the hoses or you'll have to take it back off again.

The only thing to put on is the air box now.

Slide it fully into the box the air filter is in.

It should line up pretty closely to the hoses on the carbs.

Thump the air box in the center over the carbs. This is to get it inside the two frame bars.

Double check that the hoses are lined up.

Thump it a few more times, soundly.

Tighten the clamps.

It squeezes in between the 2 frame bars so it doesn't just slip in easily. I've thumped mine in quite a few times now and it hasn't hurt it. Once it's lined up with the carb hoses it takes a few thumps. If you try to just press it in one at a time, the other just pops out. It will make you want to scream. I figured this out when I was ready to scream. I hit it and all of a sudden it was just.....in. All you need is the base of your hand and a few solid thumps. Takes 30 seconds for full install that way.

Best of luck!!!!!

[still_bluenoser]

Pod filters are not an easy fix.


Once you get it figured how to get it all together you wont have any trouble in the future.