Air box removal 5th gen

Discussion in '5th Generation 1998-2001' started by togwilson2, Oct 20, 2022.

  1. togwilson2

    togwilson2 New Member

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    Hey guys I’m currently stripping my 5th gen down to do a full restoration. Could someone let me know how the air box comes off? Do I need to drop the engine to remove it?
    Thanks
     
  2. Diving Pete

    Diving Pete Member

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  3. Diving Pete

    Diving Pete Member

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    As a little note for the uninitiated - Honda DO USE JIS screws. These look very similar to phillips / cross head screws but REQUIRE a different screwdriver. Most of the time a cross head will suffice but if I was restoring this bike then a set of those - think you will want JIS 2 & 3 will pay for themselves.
     
  4. togwilson2

    togwilson2 New Member

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    Ok thanks for your reply and yes I was actually thinking of getting a set of those JIS drivers. I have the top part of the air box off and have the bottom part detached but it looks like there are parts attached to it from underneath that I can’t get to


    Sent from my iPhone using Tapatalk
     
  5. vfrgiving

    vfrgiving New Member

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    Section 5 in the Honda service manual provides a photo guided step by step of airbox removal. A download link to a copy has been provided on the main 5th gen forum index. It's a few topics down from this one.
     
  6. Terry Smith

    Terry Smith Member

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    You'll need to unscrew the 4 air funnels in the bottom of the airbox, and after that it just lifts out with rubber hoses attached, which you'll need to detach.
     
  7. GreginDenver

    GreginDenver New Member

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    In case you're doing work without an electronic copy of the 1998-2001 Honda Service Manual VFR800FI Interceptor you should stop right now.

    Then download the manual.

    Read the manual. Get comfortable with following it step by step as you work.

    It's the only way to go.
     
    Last edited: Oct 26, 2022
    w3bdevil and Grum like this.
  8. togwilson2

    togwilson2 New Member

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    Thanks and yes I have a copy, I’m pretty handy with bikes and electrics but I’m just not familiar with the rc46 that’s all.


    Sent from my iPhone using Tapatalk
     
  9. GreginDenver

    GreginDenver New Member

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    In that case, on with the show!

    when you come to the step of removing the throttle body assembly you can go two different ways:

    1. the majority out there are "pry bar" guys, they find something long and strong and they go at it, some are careful about scratching surfaces like the bike's frame and doing things like popping edges off the throttle body casting while others are not at all careful.

    2. I choose the path less travelled, I'm a cargo strap guy. You can loop a cargo strap under one corner at the rear of the throttle body assembly and then put that loop up over your own shoulders and upper back, then tighten the cargo strap until you're a bit bent over the bike, then put your hands on the frame and gently press upward, it's very easy to control the application of force this way.

    If you want the whole thing to go even easier you can warm up the rubber "insulators" with a hair dryer or a heat gun on low setting before you do the pry or lift.

    And don't get in a hurry and forget to loosen the bands on the insulators before starting.
     
  10. vfrgiving

    vfrgiving New Member

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    I just did this job over the weekend to check the hose clamp connections on the thermostat pod. The airbox removal is very annoying, popping the throttle bodies up isn't as bad.

    The pry method should be fine as long as you stay away from any sort of metal pry bar. I will take something with a wood handle, like a ball peen hammer and flip it around. Standing on the left side of the bike, I will place the end of the wood handle between the rear valve cover and the back left corner of the throttle body. Kind of behind the throttle drum (not prying on the throttle drum). Using the rear valve cover as the pivot point, then push down towards the rear of the bike prying up on the throttle body. This is enough to pop out out the throttle body from the insulator at back left cylinder. I'll grab the fuel rails, pull up and free the rest of the throttle body assembly. When the throttle body is up, I will put some balled up paper towels into the insulators to keep stuff from falling down into the cylinders.

    I choose not to heat up the rubber insulators for throttle body install. I take a small amount of silicone o-ring Lube and lube the upper rims of the insulators near the clamps.

    FYI for the insulator clamps. Cross head fasteners on the VFR aren't Phillips, they are JIS. The little dimple punched next to the + is an identifier of a JIS fastener. Using a standard Phillips bit on a JIS fastener will cam out and damage the head. Motion Pro makes 1/4" JIS bits. Their #2 JIS bit is Motion Pro # 08-0577. You can get them off Amazon for a few bucks.
     
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