VFR 800 FI fuel lines / lower air box questions

Hi guys-
I installed a new (to me) fuel tank onto my VFR the other night, but the return line was in rough shape - at lest the outer layer. I bought some Gates FI hose from the local auto store, but getting to the fuel rail looks near impossible! It looked like I would have to remove the complete air box (lower too). I removed the velocity stacks and the screw up at the front right, but there seems to be more (much more?) holding it in place. My fist question is: Do I even need to remove the air box? And if so, how does it come off? Any pictures would be great if you have them. Take care,

 

You should download the service manual.

See this link, it's one of the first things I did when I bought my bike:
http://vfrworld.com/forums/specifications/3161-downloadable-parts-catalogs-service-manuals.html

 

Hi- I bought the FSM on CD, but it doesn't cover some things they think are basic. Where the return line connects to the back side of the fuel rail is tucked way down in there!

 

If this mis 5th Gen, then the lower is NOT difficult to remove, you just have to note where everything goes.
Get some colour tape & use it to mark anything you disconnect & mark its attachment poiunt with a corresponding piece of tape & note them individually.
From memory, the standard bike requires the rear crankcase breather to come off, the hose to the map sensor at the rear right corner & if you still have the PAIR valve then there is a hose at the front left corner under the headstock that has to come off.

Then fully losen the velocity stack screws & remove the stacks, the screws are retained in the stacks my a clip, so leave them in the stack.
Now lift the airbox & under the left middle there is an electrical connection to the white air temp sensor press to release & just in from that you will see two hole in the airbox bottom these are the IDLE vacuum air supply holes, under each is a rubber hose that connects to the idle circuit of the throttle bodies. They can be stiff to get off the airbox & a pain to get back on as you have to use your finger tips blind. once these are off the base of the airbox will lift, but DON'T pull.

On the right side there is an extension piece at the front below the sirbox, the flapper valve control solenoid is located there connnected to the Vacuum canister at the front of the airbox & a couple of other bits by hose. Disconnect the electrical connector & seperate one of the hose connnections to allow you to lift the airbox away.

If you haven't done the flapper removal mod, now is the time to do so & you can then delete all the stuff hiding around the airbox that is part of the flapper circuit.

Have fun.

 

Thanks guys. All I can say is WOW. Quit a bit of junk attaches there. The rear coils are also attached to the air box. I'm leaving those on and just pulling the plugs and primary wires. I'll see what I can do this evening. Take care,