Following Clymer instructions, I really struggled until I took the exhaust system and the chain buffer off.
The exhaust is 3 bolts and a pipe clamp and the chain buffer is 1 bolt.
It's not a doddle after that, but the access is much improved and you can see all of the obstructions to its' removal and refitment.
Just had a similar experience with the F650. When the exhaust was off it was actually very easy to take the aibox out. But I also removed all the smaal bolts that keep the box together and when I split it it came out like a dream. I also put it back in two parts and then put the small screws back. A bit off grease on the carb intake rubbers also made that go in easier.
Funduro Air box removal is a fantastic way to remove all the bad things you have in your box. I know that some people pay to write essay when they have a problem like this, but it doesn't seem quite feasible to me.
Another way is do it yourself frontal labotimy , plenty remote learning courses available, go at your own pace :-D
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