These instructions are based on a stock 2002-2003 R1. When I give an instruction labeled "left" or "right" I am looking at the perspective from the back to the front of the bike. I recommend that the bike be set on a rear stand so it is as level as possible

First you must unbolt the seat and remove it. There are two allen head bolts under the back corners of the rider seat. Gently pull up the foam edges and undo the bolts and remove them. Slide the riders seat back and remove it. Next you must unbolt the front of the gas tank. There is a single allen bolt at the front, undo it and remove it. Now you must lift the front of the tank and prop it up. I used a broom stick handle about 14" long. Wedge the stick between the location of the front tank bolt that you removed, and the bracket on the bottom of the tank.

Next you have to remove 7 screws around the lip on the mid section of the airbox and 1 on top of the airbox cover (these are all phillips head screws), and 1 larger bolt that holds down the front of the box to the frame.

Now you should be able to remove the airbox lid. Pull gently but firmly and it should come off. Remove the airfilter, It should slide straight up and out (you might want to replace it with a K&N or fresh Yamaha filter while you are in there).

Now you must disconnect the airbox pressure sensor. It is a simple clip that will come apart with a little bit of pressure to the clip. Dissconnect it and let it hang below the tank. Now disconnect the 3 tubes leading away from the back of the box. This is best done with a pair of needle nose pliers. Sqeeze the metal hose clamps together and push them futher down the hose. There should be one smaller hose at the left of the box and two larger ones in the middle. After removing the clamps, pull the hoses off of the airbox. Now you must unscrew the bolts holding the clamps together around the rubber boots at the BOTTOM of the box. The box will not come off without these loosened (I recommend using long "T" handle allen wrenches) If you look under the box you will see that they all point in different directions. THEY ARE ONLY TO BE LOOSENED, NOT REMOVED. After you loosen all four bolts the airbox bottom will slide off the throttle bodies with a little firm pressure.

WARNING: DO NOT LET ANYTHING FALL INTO THE THROTTLE BODY OPENINGS. IF ANYTHING SHOULD FALL INTO THEM DO NOT START YOUR ENGINE, IT COULD CAUSE SERIOUS DAMAGE TO THE HEAD AND CYLINDERS.

Put the box bottom on the floor and loosen the MIDDLE 2 boots ONLY with a flat head screw driver from the inside of the box. They are only made of soft rubber and should come out with a little bit of pressure, they were glued in pretty well on my R1. After they are removed, make sure no remaining glue is attached to the airbox bottom where the boots were mounted. Remove the clamps at the bottom of the boots you took out.

Next, slide the new stacks in from the BOTTOM UP, until they slide into the groove at the bottom of the new stack. The groove is about a half inch top to bottom and is the deepest indentation in the stack. It helps if you fold the top of the stack onto itself so it fits through the opening, then, grab the top of the stack after it comes through and pull it up instead of trying to push it all the way through the bottom. Inspect the bottom of the airbox bottom and make sure the stacks have sealed and make sure they hang down no futher than the existing boots on the outside holes of the box bottom. Put the clamps that you removed from the stock boots, onto the bottoms of the new stacks, making sure that they face in the same general direction as the remaining clamps that were not removed on the outside boots.

Before re-installation, clean out the inside of the airbox bottom with a damp rag. Make sure there is no debris left in the box bottom that could get sucked into the motor upon restart.

Now remount the box bottom onto the throttle bodies. Set it down on the bodies so that all boot bottoms are touching and then press down evenly until the boots drop down over the bodies. Stick your finger into the boots and stacks to feel for any gaps between the throttle bodies and the boot bottoms. If there is a gap push down on the box bottom at that opening until it seals.

Tighten the clamps at the bottoms of the boots and stacks until they are snug. Do not over tighten or they will strip. Make sure you tighten all four. Reconnect the airbox pressure sensor. Reconnect the three hoses and slide the hose clamps up to the top with your pliers. Locate the "FRONT" marking on the airfilter. Slide the airfilter straight down into the box making sure that it stays inside the slots on either side and the "FRONT" marking is facing forward. Make sure there isn't a gap at the bottom of the filter where it meets the box bottom. Slide the box top straight down onto the box bottom and the airfilter. Make sure you line up the airfilter with the slots on the inside of the box top. Replace the top screw on the airbox, then replace the 7 surrounding screws. Make sure you tighten them evenly around the box. Replace the airbox front mounting bolt. Remove the gas tank support and lower the tank back down onto the frame. Replace the gas tank front mounting bolt. Slide the riders seat back to front up against the rear of the gas tank. Replace the two bolts under the rear corners of the riders seat.

Velocity Stacks

Velocity Stacks

That looks sw33t mangus.. I'll have to put some of thoes on... after I get my bike street worthy again.. :thumbup

I was curious.. Why, when we install the Stacks, do we only do the inside 2? What about the outside ones?