How to remove the AIR BOX on a Triumph Bonneville T100 / T120Updated 2 years ago

How to Remove the Air Box

Bonneville T100 Liquid

The how-to guide is proved for information purposes only.   The guide assumes you have general mechanical knowledge and have the ability to remove and replace components on your motorcycle.  If you have any questions or are not comfortable doing the work contact a professional mechanic. Keep all stock parts from your existing system as some components may be necessary to install your new British Customs Products depending on the application. 

Read through the guide prior to beginning to remove any components.  Always properly support the vehicle with a stand and/or lift when servicing or performing any work. Unstable vehicles my present dangerous conditions and may cause property damage and/or personal injury

Step By Step Guide - How to Remove the Air Box

1. Remove the seat

2. Disconnect the Battery

3. Remove the fuel tank (see How to Remove the Gas Tank)

4. Remove the left and right side panels by pulling them away from the bike 

5. Remove the rear wheel (see How to Remove the Rear Wheel)

6. Remove the rear fender (see How to Remove the Rear Fender)

7.  Using a 3mm Allen remove the (2) bolts and (2) washers located on the right side of the bike that secure the evaporative canister

8.  Using a 7/64  Allen, remove the (1) bolt that secures the engine breather hose to the air filter cover.

 9. Remove the two hose clips and remove the engine breather hose.  

10. Using a T20 Torx, remove the (1) bolt that secures the air intake temperature sensor to the airbox. 

Pro Tip:  Install the screw in the hole to keep aid in installation

11. Using a 7mm socket, remove the (2) bolts that secure the fall detection switch to the air box

Pro Tip:  Install the screw in the hole to assist in installation

12. Remove the fuse box and diagnostic connector from the airbox by pulling the connector away from the bike. 

13. Using a T20 Torx, remove the (1) bolt and (1) washer that secures the air intake duct.  located on the left-hand side of the bike.

Note: The seal for the air intake may fall off with the air intake duct

14. Remove the lower hose from the purge control valve

15. Using a T20 Torx, remove the (1) bolt that secures the purge control valve and bracket to the airbox.

16. Remove the alarm multi-plug from the airbox

17. Using a T20 Torx, remove the (2) bolts that secure the rollover valve and bracket to the airbox,. 

18. Move the rollover valve bracket and detach the ambient air pressure sensor hose from the airbox.

19. Remove the starter motor solenoid from the relay bracket by pulling away from the bike.  The starter motor solenoid is located on the right side of the bike.

20. Using a T20 Torx, remove the (3) bolts that secure the relay bracket to the airbox.

21. Using a 3mm Allen,  Loosen the clamp for the throttle body intake hose.  The clamp is located on the left side of the bike.  

Note: The position of the clamp for installation. 

22. Using a 30 Torx, remove the (2) bolts and (2) shouldered washers from the backside of the airbox.  Located underneath the subframe.  

 23. Using a T30mm Allen, remove the (1) bolt and (1) shouldered washer from the left side of the airbox.

24. Using a T30 Torx Allen, remove the (1) bolt and (1) shouldered washer from the right side of the airbox. 

25. Remove the air box by maneuvering the airbox toward the rear of the motorcycle. 

Note:  When removing the air box, ensure that the harness and hoses on the left side of the frame do not get damaged