Step 5: Air inlet
Before you start this step you need to make sure that you have the right carb inlet box. SJ makes two versions of this box depending upon the height of your carb. The one that comes with the kit assumes you have a newer carb that is tall. Some carbs (like my MA4-5) are shorter. The nozzle on the carb inlet box is angled differently. Confer with Will/Liz on whether you have the right version.
A small fiberglass box is mounted to the bottom of the carb to act as an air box. To the front of that box is a conical shaped box that contains the air filter and alternate air door.
Sand the edges of the mating surfaces of the inlet air box smooth. (Don't sand off the buttons and matching dimples!) Install nutplates around the perimeter of the upper portion. These will hold the two halves together.
Next you will need to mount the upper half to the carb. Prior to mounting the carb on the engine you might go to the trouble of creating a template of the carb itself getting the holes layed out. The carb is not centered on the bottom of the engine, so the air inlet box gets offset to the right of the carb. Important: Position the carb inlet box as far AFT as possible. This will help fitting the filtered airbox later. (The photo's below do not show accurate AFT positioning.)
I'm sure all carbs are a bit different from each other. The upper half has a small depression on the aft edge to clear the carb drain boss. My carb (MA4-5?) also had another protusion on the bottom. I made cutouts for these protusions in the box and drilled the holes using the template I made prior to mounting. I'll cover up the holes with some fiberglass layups.
January 6, 2006
The carb inlet box I was given wouldn't work for my setup. The stock box is designed for taller carbs. Mine is a short carb. Will made up a new box that has less of an angle on it. The newer box solved my fit problems.
2.5 hours installing new carb box.
A small fiberglass box is mounted to the bottom of the carb to act as an air box. To the front of that box is a conical shaped box that contains the air filter and alternate air door.
Sand the edges of the mating surfaces of the inlet air box smooth. (Don't sand off the buttons and matching dimples!) Install nutplates around the perimeter of the upper portion. These will hold the two halves together.
Next you will need to mount the upper half to the carb. Prior to mounting the carb on the engine you might go to the trouble of creating a template of the carb itself getting the holes layed out. The carb is not centered on the bottom of the engine, so the air inlet box gets offset to the right of the carb. Important: Position the carb inlet box as far AFT as possible. This will help fitting the filtered airbox later. (The photo's below do not show accurate AFT positioning.)
I'm sure all carbs are a bit different from each other. The upper half has a small depression on the aft edge to clear the carb drain boss. My carb (MA4-5?) also had another protusion on the bottom. I made cutouts for these protusions in the box and drilled the holes using the template I made prior to mounting. I'll cover up the holes with some fiberglass layups.
January 6, 2006
The carb inlet box I was given wouldn't work for my setup. The stock box is designed for taller carbs. Mine is a short carb. Will made up a new box that has less of an angle on it. The newer box solved my fit problems.
2.5 hours installing new carb box.
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