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Discussion Starter · #1 ·
How do I remove the airbox on this thing? I can't even find a video or discussion for removal on the 790.
Help please!
Thanks,
Lonny
 

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Discussion Starter · #3 ·
There is no service manual for the 890 yet, and the only info I can find for the 790 is for the adventure,, and it's different than the Duke.
 

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This vid shows the process of removing the air filter but not the entire air box.
M5 screws with 3Nm (2.2 lb ft) torque

If you look carefully on this site you can find the 2018 790 duke service manual where I pulled this from:
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Though maybe you meant literally how to REMOVE THE BOX. I have no idea then...
 

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There is no service manual for the 890 yet, and the only info I can find for the 790 is for the adventure,, and it's different than the Duke.
I was referring to the 790D service manual here on the forum.
 

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Removing the filter box - AFAIK - is a real serious operation.

You will need to split the rear subframe as there is a brace that runs side to side through a special triangular tube in the airbox.
As well as the manual - which is comprehensive - I would suggest you study the parts fiche - easily visible online.

So far the evidence suggests no real advantage - the Helmholz effect of the airbox is well developed esp at higher rpms.
I have seen an airbox elimination kit - but the guy in Austria who developed it seems to have dropped off the map.
But he proffered it was more a gain at midrange. And he confessed that stock fuelling did not cope.

I would suggest that you will need also to look at a PCV (fuel and ignition) or COOBER as well.
 

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Discussion Starter · #7 ·
When installing the PC V, it states to remove the seat, tank and airbox. I'm sure this is to get better access too the throttle bodies. A link to the Duke service manual would be great. I have found and downloaded the manual from KTM, but it is the adventure manual, not the Duke as indicated. Thanks.
 

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When installing the PC V, it states to remove the seat, tank and airbox. I'm sure this is to get better access too the throttle bodies. A link to the Duke service manual would be great. I have found and downloaded the manual from KTM, but it is the adventure manual, not the Duke as indicated. Thanks.
When I installed my PCV I just took the seat and tank off ,not the air box .
 

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Discussion Starter · #10 ·
My big hands didn't fit. If you loosen the 4 large subframe bolts and remove the top 2, the whole subframe tilts away and down to rest on the back tire. That creates some good work space. Getting the throttle body boots back into the air box was easy too. The right cylinder coil connecting was a *****. Is all back together with the Akropovic full Ti exhaust, PCV and the charcoal canister delete. Looks good, sounds good, it's lighter and I can't wait to do some ripping tomorrow after work.
Thanks for the help and the link.
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My big hands didn't fit. If you loosen the 4 large subframe bolts and remove the top 2, the whole subframe tilts away and down to rest on the back tire. That creates some good work space. Getting the throttle body boots back into the air box was easy too. The right cylinder coil connecting was a *. Is all back together with the Akropovic full Ti exhaust, PCV and the charcoal canister delete. Looks good, sounds good, it's lighter and I can't wait to do some ripping tomorrow after work.
Thanks for the help and the link. Let’s see pics of the RG 500 Gamma👀
View attachment 4541 View attachment 4542 View attachment 4543
 

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Today I sat down and thought about removing the entire airbox. I changed my mind after figuring out that I would have to remove the entire tank to make enough room to work.
I did however remove the left side of the sub-frame which was quite easy. You just have to have the right tools to be able to remove some small screws from behind the sub-frame and inside the battery housing.

Reassembly is a piece of cake as well, but you have to make sure that the holes of the screws align perfectly. I might do a video or upload some pictures in the future showcasing how it's done since I'm thinking of taking apart the entire bike for cleaning and a thorough check.
 
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