snaked from SP125 Limited Airbox Fitting Instructions v1
31 Bartle Gill Drive,  Baildon,  Shipley,  West Yorkshire,  BD17 6UE,  England
Telephone 01274 592035      Fax 01274 598363      Mobile 07738 626165
www.sp125racing.com
1995/2006 RS125R RAM AIRBOX KIT
		FITTING INSTRUCTIONS
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1	RE-POSITIONING THE IGNITION COIL
	It is necessary to reposition the ignition coil as it is not possible to fit the airbox with the coil in the
	original position.  Remove the coil and grind away the cast mounting lugs on the frame to make
	room for the Airbox.  Mount the coil to the right side front engine spar, using 2 aluminium spacers.
	You can either drill the spar and bolt the spacers from the engine side, or weld the spacers to the
	spar.  The span of the coil spacers necessary is 60mm.
2	RAM AIRBOX
	For easier fitting and removal of the airbox, cut back the seat sub frame at the front by approx
	5 ~ 10mm.  Fit the rubber foam strips around the top of the airbox to seal it with the fuel tank.
	The fuel tank will then hold the airbox in position.
3	RADIATOR
	To enable the airbox scoop to fit underneath the frame headstock, the radiator must be lowered.
	Make longer radiator brackets (Approximately 25mm) to mount the radiator lower and remove the
	rib on the top of the radiator.  It may be necessary to then cut out part of the bottom fairing.
	Note: If fitting the letterbox type airbox, it will be necessary to cut out part of the left side header
	tank of the radiator to allow the airbox side pipe to pass the radiator.
4	CARBURETTOR VALVE SLIDE
	Drill a small hole (Ø 1.0mm ~ 1.5mm) in the outside face of the carburettor slide, centrally, at a
	distance of 16.5mm from the top of the slide.
5	FUEL TANK CAP - 1995~1999
	Drill a larger hole in the fuel tank cap (If using 1995~1999 plastic fuel cap) and the rubber seal to
	Ø 3.00mm and remove the foam piece from between the cap and the rubber seal.
6	GEARBOX OIL BREATHER PIPE
	Remove the black rubber pipe from the gearbox breather, under the carburettor.
	This part is not necessary.
7	THROTTLE & CLUTCH CABLE
	Feed the throttle cable through the airbox at the front left side.  When you remove the airbox
	always remove the throttle cable completely from the carburettor top etc.
	The clutch cable will feed as normal, underneath the airbox.
8	INITIAL CARBURATION SETTINGS
	When using ram airbox system you must use richer Main Jet and Needle Jet.
	If weather conditions similar to last time using without airbox, then start initially with Main Jet 2
	sizes richer and Needle Jet 1 size richer and on 1 clip position richer.
9	BREATHER PIPE AND BOTTLE FITTINGS
	Take off original fuel overflow bottle and replace with ram airbox kit bottle supplied.
	Be sure to fit both pipes as shown below and make sure the pipes are not trapped or bent so that
	air cannot pass.  Fix the breather bottle to the side of the left side front engine spar.
	*Note 1: It is essential that the fuel tank remains the same pressure as inside the ram airbox,
	otherwise the engine will give misfire due to fuel starvation.  This is because the fuel is gravity fed
	to the carburettor and if the pressure is greater in the airbox than the fuel tank, then the fuel will not
	feed to the carburettor and the engine will misfire or stop at high speed / rpm.
	*Note 2: It is normal for some fuel to be in the breather bottle after each practice or race.
	This is caused by the fuel passing into the breather pipe during heavy braking.
	Be sure to empty breather bottle between practice or race to avoid air blockage if bottle gets full of
	fuel as this will stop pressure in fuel tank and ram airbox from being equal.
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