How to Remove Ski Doo Airbox in 5 Easy Steps

Ski-Doo owners who are looking to upgrade their snowmobile’s air filter or clean the airbox may be wondering how to remove the airbox safely and efficiently. Removing the airbox can be a challenging process, but with the right tools and guidance, it can be done quickly and easily. In this article, we will walk you through how to remove your Ski-Doo airbox in just 5 easy steps.

Step 1: Before you begin, ensure that you have all the necessary tools, including a screwdriver, pliers, and a new air filter. It is also important to ensure that you are working in a clean, well-lit area.

Step 2: Disconnect the battery to avoid any electrical issues during the process. It is essential to do this step to ensure your safety while removing the airbox.

Step 3: Remove the airbox cover and filter. This step will require the use of your screwdriver and pliers. You may also need to use a bit of force to remove the cover and filter, but be careful not to damage the airbox or any other parts of the snowmobile.

If you’re looking to improve your Ski-Doo’s performance, cleaning or replacing the air filter is a great place to start. With these easy-to-follow steps, you can remove the airbox yourself and save time and money. Keep reading to learn the remaining steps, and you’ll be an airbox removal pro in no time!

Step 1: Prepare the Tools You Will Need

Before you start removing your Ski Doo Airbox, make sure you have all the necessary tools handy. The last thing you want is to realize mid-way that you don’t have a tool you need. Here are the tools you will need to complete this task:

• Screwdriver: You will need a screwdriver to remove the screws that hold the airbox cover in place.
• Pliers: You will need pliers to disconnect the air temperature sensor from the airbox.
• Wrench: You will need a wrench to disconnect the battery cables.
• Clean Cloth: You will need a clean cloth to wipe the airbox and the surrounding area.

Make sure to have all these tools within reach before you begin to remove your Ski Doo Airbox.

Remember, safety should always be your top priority when working on your snowmobile. Wear gloves and protective eyewear to prevent injury while handling tools.

Once you have all your tools ready and you have taken the necessary safety precautions, you can proceed to the next step in removing your Ski Doo Airbox.

Read on to learn about the next step: Disconnect the Battery.

Gather the Necessary Tools

1. Safety first: Before starting the process, make sure you have safety glasses and gloves to protect yourself.

2. Basic tools: You will need a screwdriver, pliers, and sockets to remove the airbox.

3. New air filter: Purchase a new air filter to replace the old one.

Now that you have gathered all the tools needed, you can begin the process of removing the Ski Doo airbox. It’s important to have all the necessary tools beforehand to make the process as smooth as possible. The next step is to disconnect the battery to ensure safety.

Make Sure You Have the Right Parts

Before starting, make sure you have all the necessary parts for the airbox removal process. You will need a socket wrench set with various socket sizes, a pair of pliers, and a flathead screwdriver. Check your Ski Doo owner’s manual to see if there are any specific tools you will need for your particular model.

It’s also essential to make sure you have the right parts for reinstallation. If you need to replace the air filter, order a new one ahead of time. You should also have a new airbox cover gasket on hand. It’s a good idea to inspect the air temperature sensor and the intake boots for any damage or wear and replace them if needed.

If you’re not sure which parts to order, consult a Ski Doo dealer or a knowledgeable mechanic. They can help you find the right parts for your specific Ski Doo model.

Step 2: Disconnect the Battery

Before starting any work, it is important to disconnect the battery to avoid electrical shocks or damage to the electronic components. First, locate the battery, which is usually found on the side of the sled. Use a wrench to disconnect the negative terminal, which is the black cable.

Next, remove the plastic cover on the side of the sled to expose the wiring harness. Look for the connector that goes to the ECM, which is the Engine Control Module. Unplug the connector by pressing on the release tab and pulling gently.

Finally, locate the connector that goes to the handlebar warmers and unplug it. The handlebar warmers are connected to the battery, and they can drain the battery if left connected while working on the airbox. Be careful not to damage any of the wires or connectors while working.

Locate the Battery

Before disconnecting the battery, you need to know where it is located. Most Ski Doo models have the battery located under the seat or in the front storage compartment.

Refer to your Ski Doo owner’s manual if you are unsure of the battery’s location. You can also check the manufacturer’s website for more information.

Once you have located the battery, make sure the engine is turned off and the key is removed from the ignition.

Step 3: Remove the Airbox Cover and Filter

Locate the Airbox Cover and Filter: The airbox cover and filter are typically located near the front of the engine compartment. You may need to refer to your Ski-Doo owner’s manual to find the exact location.

Remove the Airbox Cover: Use a screwdriver or socket wrench to remove the screws or bolts that hold the airbox cover in place. Place the screws or bolts in a safe location where they won’t get lost.

Remove the Air Filter: The air filter is typically secured in place with clips or a clamp. Gently remove the clips or loosen the clamp and carefully remove the air filter from the airbox. Inspect the air filter for damage and replace it if necessary.

Clean the Airbox Cover and Filter: Use a clean rag or compressed air to remove any dirt or debris from the airbox cover and filter. Be sure to clean the airbox thoroughly to prevent any debris from entering the engine.

Replace the Airbox Cover and Filter: Once the airbox cover and filter are clean, reattach the air filter to the airbox and secure it in place with the clips or clamp. Then, reattach the airbox cover using the screws or bolts you removed earlier.

Remove the Airbox Cover

Step 1: Locate the airbox cover. It’s typically located on top of the engine and is connected to the carburetor with a rubber duct.

Step 2: Loosen the hose clamps that connect the airbox cover to the rubber duct. You may need pliers or a screwdriver to do this, depending on the type of clamp used.

Step 3: Remove the bolts or screws that hold the airbox cover in place. Depending on the make and model of your Ski Doo, there may be one or more bolts/screws holding the cover in place.

Step 4: Carefully remove the airbox cover from the carburetor. You may need to wiggle it a bit to get it loose, but be careful not to damage any of the parts.

Step 5: Set the airbox cover aside, making sure to keep track of any bolts or screws that were removed so they can be put back in place later.

Removing the airbox cover is an important step in accessing the air filter and other parts of the carburetor. Follow these steps carefully to avoid damaging any of the parts or connections, and to ensure a smooth reinstallation process later on.

Remove the Filter

Once the cover is off, the filter will be exposed. It is typically held in place by a metal clip or a plastic knob.

Depending on the model, you may need to remove the air intake tube to access the filter.

Carefully detach the clip or knob and remove the filter.

Inspect the filter for damage, dirt or debris. If the filter is dirty, it should be replaced.

If the filter is in good condition, set it aside in a clean, safe place until it’s time to reassemble the airbox.

Clean the Airbox Area

After removing the filter, it’s a good idea to clean the airbox area before installing the new filter. Use a clean cloth to wipe away any dust or debris that has accumulated in the airbox. This will help ensure that your new filter stays clean and functions properly.

Make sure to also check the airbox for any signs of damage or wear. If you notice any cracks or holes in the airbox, it may need to be replaced before installing the new filter.

Finally, check the sealing surface of the airbox where the filter sits. If there is any dirt or debris on the sealing surface, it can prevent a proper seal and allow unfiltered air to enter the engine. Use a clean cloth to carefully clean the sealing surface before installing the new filter.

Step 4: Disconnect the Air Temperature Sensor

The air temperature sensor is a small device located on the air intake tube. It measures the temperature of the air coming into the engine and sends that information to the engine control module.

To disconnect the air temperature sensor, you will need to locate it on the air intake tube. It is usually a small plastic plug with wires coming out of it.

Use a flathead screwdriver to gently pry up the tab on the connector and pull it apart. Be careful not to damage the wires or the connector itself.

Once the connector is disconnected, carefully set it aside so that it doesn’t get lost or damaged while you continue working on the air intake system.

Locate the Air Temperature Sensor

The air temperature sensor is usually located in the air intake system or the air filter housing. It’s a small electronic device that measures the temperature of the air that’s entering the engine.

It’s important to locate the sensor before attempting to disconnect it. Refer to your vehicle’s manual or a repair manual for specific instructions on where to find it.

Once you’ve located the sensor, inspect it for any damage or signs of wear and tear. If you notice any issues, it may be time to replace the sensor before reconnecting it.

Disconnect the Air Temperature Sensor

Step 1: Locate the air temperature sensor connector, which is typically found on the air intake duct or the airbox.

Step 2: Carefully unplug the connector from the air temperature sensor. Some sensors may have a locking mechanism that needs to be released before the connector can be removed.

Step 3: Once the connector is removed, inspect it for any signs of damage or corrosion. If any issues are found, the connector should be replaced before reconnecting the sensor.

Step 4: Set the connector aside and ensure that it won’t interfere with any other parts while you continue working on the airbox or filter.

Step 5: Remove the Airbox and Clean the Area

Disconnect the electrical connector: Before you can remove the airbox, you need to disconnect the electrical connector from the mass airflow sensor. Use your fingers to depress the locking tab and then pull the connector away from the sensor.

Remove the bolts and screws: With the electrical connector disconnected, you can remove the bolts and screws that hold the airbox in place. You may need to use a socket wrench or pliers to remove some of the bolts or screws.

Lift the airbox out: Once all the bolts and screws are removed, you should be able to lift the airbox out of the engine bay. Be careful not to damage any hoses or wires that may be attached to the airbox.

Clean the area: With the airbox removed, you can use a clean rag or towel to wipe down the area where the airbox was sitting. This will remove any dirt or debris that may have accumulated in the area.

Reinstall the airbox: Once the area is clean, you can reinstall the airbox by reversing the removal steps. Make sure all bolts and screws are tightened properly and the electrical connector is reconnected to the mass airflow sensor.

Remove the Airbox

Now that the airbox cover and filter have been removed, you can proceed to remove the airbox itself. This may require loosening some bolts or clips that hold it in place. Be sure to refer to your vehicle’s owner manual for specific instructions.

Once the airbox is free, you can take it out of the engine bay and set it aside. This will give you better access to the area around it, allowing you to clean it thoroughly.

Make sure to inspect the airbox for any damage or wear while it is out. If it appears damaged or worn, it may need to be replaced.

Clean the Airbox Area

After removing the airbox, it is important to clean the surrounding area before installing a new one. This will help prevent any debris or dirt from entering the engine and causing damage. Here are some steps to follow:

• Remove debris: Use a clean rag or compressed air to remove any loose debris or dirt around the area. Be careful not to push any debris into the engine.
• Clean the area: Use a degreaser and a clean rag to clean the area around the airbox. Be sure to remove any oil or grime that may have accumulated.
• Inspect the air duct: Inspect the air duct leading to the throttle body for any damage or signs of wear. Replace if necessary.

Once the area is clean and the air duct is inspected, you can install the new airbox. Make sure to secure it properly and reattach any hoses or electrical connections that were removed.

Inspect the Airbox and Filter

After you have cleaned the airbox area, it’s a good idea to inspect the airbox and filter for any damage or signs of wear and tear. Look for any cracks, holes, or other damage that could affect the performance of the air filter. If you notice any damage, it’s best to replace the airbox or filter as soon as possible.

Inspect the air filter for any dirt, debris, or other contaminants that could be restricting airflow. A dirty air filter can cause reduced performance and even engine damage if not addressed. If the filter is dirty, it’s time to replace it. Most air filters should be replaced every 12,000 to 15,000 miles or as recommended by your vehicle manufacturer.

Finally, make sure the air filter is properly seated in the airbox and that all clamps and fasteners are secure. Any air leaks can affect the performance of the engine, so it’s important to ensure everything is properly tightened and sealed.

Pro Tip: Reinstalling the Airbox

Be gentle with the sensors and wires: When you’re reinstalling the airbox, make sure you don’t damage any of the sensors or wires. They can be fragile, and if you break them, it can be expensive to replace them.

Use the right tools: You’ll need the right tools to properly reinstall the airbox. Make sure you have the correct size socket wrenches and screwdrivers for your particular vehicle.

Double-check your work: After you’ve reinstalled the airbox, double-check all of your connections and make sure everything is secure. Start your vehicle and listen for any unusual sounds or vibrations. If everything sounds good, you’re good to go!

Make Sure the Airbox is Aligned Correctly

• Check for proper fit: Make sure the airbox is securely in place and all fasteners are tightened properly.

• Inspect hoses and connections: Ensure all hoses and connections are properly connected and tightened. A loose or disconnected hose can cause a vacuum leak, which can lead to engine performance issues.

• Confirm sensor connections: Check that all sensors and electrical connections are properly connected and seated.

After reinstalling the airbox, start the engine and listen for any unusual sounds or vibrations. If you notice any issues, turn off the engine and double-check that the airbox is correctly aligned and all connections are secure. It’s always better to take the extra time to ensure everything is properly installed than to risk damaging your engine or other components.

Double Check All Connections

After reinstalling the airbox, it’s important to double check all connections to ensure that everything is properly secured.

Check the air filter, MAF sensor, air temperature sensor, and any other components that were removed or disconnected during the process. Make sure all clips, hoses, and electrical connections are properly connected and tightened.

It’s also a good idea to start the engine and let it idle for a few minutes to ensure that everything is running smoothly and there are no warning lights or error codes.

Frequently Asked Questions