Spark plug change, remove the air box lid and complete air box removal 

By Allen Ulmer aka SRXSPEC

This will walk you through how to change the spark plugs, remove the air box top, and remove the air box itself.

First we'll start with the tools needed.

-4mm "T" handled Allen Wrench
-5mm "T" handled Allen Wrench
-1/4" drive ratchet
-Short 1/4" drive extension
-1/4" drive 10mm socket

Next I assume most of you know how to remove the side panels and center section of the hood, but here's a good picture showing the dsuz fasteners anyways!

The easiest way I've found to remove the side panels is to give a gentle tug on the front and then slide it down and forward and they will come right off.

For the hood I like to grab the outside edges, lift up slightly, and slide it towards the front of the snowmobile until it comes off the hook in front.

On the access panel in between the handle bars and the gauge pod there is four 5mm Allen head 1/4 turn fasteners that need to be turned. This panel also has 3 tabs that slide into the gauge pod and can make it difficult to pull it up or remove it.

Next we'll talk about getting to the spark plugs. This is my way of doing it only. There may be faster or simpler ways, but this is the way that I've found to allow the best access and also is fairly fast. I like to loosen the head light and slide it forward and out of the way.

First loosen the accessory panel 1/4 turn Allen head fasteners.

Second there is a bolt on each side of the head light that requires a 10mm socket to loosen. Loosen and remove these and slide the head light forward and let it sit on the air box.

Then I like to disconnect the key switch and simply slide the access panel around the steering post and let it sit on the fuel tank cover.

Last you now have open access to the spark plugs. Remove the 10mm bolt on each spark plug cap and use the spark plug wrench in your tool kit to remove or replace all the spark plugs. This will take roughly 5 minutes from start to finish if you had to change a plug on the trail, but I doubt that will ever be needed!

Next we'll talk about air box top removal.

If you read along above you'll see we now have the head light loose. I like to lift the head light up and move it back where the accessory panel would sit to allow us easy access to the air box top.

First you'll have to unlock the 4 latches that sit on each corner.

You'll see there are 3 slots and tabs that help align the air box on the back. To remove the air box lid you must lift the front (closest to the bumper) of the air box lid up and it will disengage the tabs in the rear, the same goes for reassembly, position the front up and slide the tabs in and close it.

Last but certainly not least we'll talk about air box removal.

I like to remove the head light completely for this task. Since it is already loose all we have to do is simply unplug the two plug-ins that run to it.

First you will need to take your 4mm wrench and loosen all four of the clamps holding the air box onto the throttle bodies.

Second you will need to unhook the rubber strap on the front of the air box so you can lift and manuever the air box.

Third we will then unhook the air temp sensor that is in the side of the air box.

After unhooking the temp sensor you should be able to lift the air box slightly and unhook the crankcase vent going into the bottom of the air box.

Next we will unhook the line going to the manifold pressure sensor.

Lastly we will unhook the drain line running from the bottom of the air box and the air box is now free and removed!