Modern Classics Air Box Removal Kit
Contents
1. Step 22 Optional The sensor removed in Step 10 may throw a check en gine light if not reinstalled Remove the sensor mount from the stock air box using a 5 mm allen Step 23 Optional Plug the sensor into the mount Zip tie the sensor to a wiring harness to prevent dangling Step 24 Reinstall the solenoid starter and turn signal relays by sliding them onto the new brackets on the battery box Modern Classics Air Box Removal Kit BRITISH CUSTOMS Step 25 Install the new crankcase breather filter We suggest cutting the crankcase hose so that the filter sits under the throttle body or car buretor Step 26 Attach the supplied K amp N Air Filters to the throttle body carburetor Tighten the clamps down with a flathead screwdriver Step 27 Reinstall the rear wheel while keeping the spacers in place hold ing the rear brake caliper in its position and aligning the rotor be tween the pads Then set the chain in place Step 28 APPEAR Before running the axle through the wheel make sure the swingarm caliper mount wheel holes and spacers are lined up Then run the axle through from the brake side and loosely tighten it ge n a A LE LEDERER o ET f Modern Classics Air Box Removal Kit BRITISH CUSTOMS Step 29 Use an 8 mm wrench adjust the chain tensioners and set to specifi cations Step 30 Tighten the rear axle down with a 19 mm wrench on the brake side and 242. Modern Classics Air Box Removal Kit BRITISH CUSTOMS Kit Includes Fits The Following Motorcycles Tools Required A a eee poor e Triumph Bonneville e 5 3 4mm Allens u AR igh Flow Air Filters e Triumph Bonneville EFI e T30 A n seg a neo Filter e Triumph Thruxton e 19 24 8 mm Wrenches Carbureted Only e Triumph Thruxton EFI e Torque Wrench 5 Jet Kit Carbureted Only e Flathead amp Phillips Screwdriver 6 Hardware This is a high performance product and intended for race use applications USE AT OWN RISK Please be advised that in California this product is intended for Racing vehicles only A Racing Vehicle is defined to mean a com petition vehicle not used on public highways It is not enough that the vehicle will be used for off road use It must be for competition use only and for closed course competition use only The manufacturer and retailer assume no responsibility for any use or application of this product in violation of any applicable law Be fore installing this product please check your state province and local municipal laws and regulations WARNING It is recommended that this kit be installed by a certified Triumph technician following the Triumph service manual to aid in proper fitting Verify all torque specs in Triumph service manual Other Items We Think You May Like Side Cover Screws Front Sprocket Cover Oil Pressure Guage Keihin CVK Choke Knob Modern Classics Air Box
3. Removal Kit BRITISH CUSTOMS step 1 Start by removing the stock seat with a 5mm allen Step 2 Remove the side covers using a flathead screwdriver Step 3 Disconnect the battery negative black side first with a Phillips screwdriver Remove the battery retaining strap Step 4 Remove the ECU retainer and battery spacer Now you can remove the ECU and battery Modern Classics Air Box Removal Kit BRITISH CUSTOMS Step 5 Disconnect the taillight and turn signal harnesses step 6 Remove the fender bolts using a T30 Note Be careful to not let the fender drop when removing the bolts Step 7 Slide the solenoid starter and turn signal relays from the mount ing brackets Sten 8 Using an 8 mm socket remove the air intake from the air box on the left side of the bike Remove the stock air filter Modern Classics Air Box Removal Kit BRITISH CUSTOMS Step 9 Remove the rear brake reservoir and the fuse box using a 5mm al len Keep the brake reservoir upright to avoid leaking Step 10 Remove the air box sensor step 11 Using a 3mm allen loosen the airbox manifold clamps step 12 Remove the secondary air injection SAI hose that runs along the bottom left side of the tank from the air box to the SAI solenoid Modern Classics Air Box Removal Kit BRITISH CUSTOMS Step 13 Using a jack lift the bike from the center of the frame to allow for better access to the ai
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5. mm wrench on the drive side then torque down to 85 Nm Note It is now safe to remove the jack from the frame Step 31 Install the ECU battery and spacers into the new battery box and secure using the stock strap Step 32 Reattach the rear fender to the frame using the stock hardware and a T30 Tighten and torque these 4 bolts to 9 Nm Modern Classics Air Box Removal Kit BRITISH CUSTOMS Step 33 Reconnect the taillight and turn signal harnesses After making sure all the wiring harnesses are mounted properly and have been connected re connect the battery starting at the positive terminal Step 34 Reinstall the side covers with a flathead screwdriver Step 35 Reinstall the seat using the stock hardware and a 5mm allen Note For proper performance it is required that the motor cycle is re jetted or re mapped immediately after install Please be advised that in California this product is intended for Racing vehicles only A Racing Vehicle is defined to mean a competition vehicle not used on public highways It is not enough that the vehicle will be used for off road use It must be for competition use only and for closed course competition use only The manufacturer and retailer assume no responsibility for any use or application of this product in violation of any applicable law Before installing this product please check your state province and local municipal laws an
6. r box Step 14 Remove the rear axle using a 19mm wrench on the brake side and a 24 mm wrench on the drive side Loosen the chain tensioners with an 8 mm wrench Step 15 Pull the chain off the rear sprocket and let it hang on the swingarm Roll the rear wheel out while guiding the wheel spacers and brake caliper off the wheel as you remove Note To prevent the caliper from swinging during the install we secured it to the swingarm with tape Step 16 Remove the 4 air box bolts in the battery box using a T30 The air box will now be loosely hanging from the manifolds Modern Classics Air Box Removal Kit BRITISH CUSTOMS step 17 Pull the air box from the stock manifolds and remove the crank case breather hose connected to the lower front of the air box Re move air box through the back of the frame Step 18 Install British Customs Battery Box and mount it in place with the supplied hardware using a 4mm allen Step 19 Remove the fuse box and the rear brake reservoir from the old bracket The fuse box is held in place by a plastic push in clip Simply pry it out with a flathead screwdriver The brake reservoir comes off with an 8mm wrench Step 20 Using the supplied hardware attach the fuse box to the new bat tery box with a 4mm allen Modern Classics Air Box Removal Kit BRITISH CUSTOMS step 21 Attach the rear brake reservoir to the battery box with the supplied hardware and a 4mm allen
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