trying new/used digicam Airbox mod KZ440

[Blueknyt]

ok, got a new, well used cool cam from a friend of mine. figured i'd give it a go while i was modding an Airbox for my kawi


This is the airbox carbside and Aircleaner assembly side




The aircleaner assembly bolts onto the side with the squarish holes. it is very restrictive and affects the jetting, being as i cant seem to locate one used, in good shape, and not made outta gold, (30$ cheapest found) im going to have to rejet anyway, but dont want to give this bike to my friend with no filter system or one so elaborate he cant take care of it.

so having a few spare parts laying around from other projects, i go to modding the box to use a K&N from another bike. the box is in frame tight, batt sits behind but a little lower in the frame, no room on sides and top has frame works over it, Right Srinath?

My solution was to block the normal holes for the assembly and make one to fit the K&N.

ok, wanting the K&N centered, i had to clear away the divider


using some Flat plexi i had


i proceeded to trim to size and cut a hole with an Air Diegrinder and heated and bent an edge to fit over the top, with 2 smaller holes drilled for bolts to help hold the plexi on.

here is another shot of the cut plexi and the K&N that is going to be fitted to it. the large hole in the plexi is just smaller then the OD of the K&N, it will hold itself in.


now seal the plexi to the airbox with thin layer of RTV and bolts from top to hold it down


the last bit is to plug the filter in the hole


this filter is no thicker then the stock aircleaner assembly and clears the battery without an issue, now i just have to put the box back in, get the jets for the carbs and make it purr again. then it leaves and a 94 Katana 600 slides into its spot, yippy!

camera seems to work ok i guess. if i can just get caught up with everything i need to get done, i would love to do other write ups.

Opinions?

[The Buddha]

That's so cool ... how did you roll a lip into that round hole large enough for the air filter and still have it nice and round ... and BTW I suggested a lot of small holes in that plate and put a swatch of Filter foam and tape it in ... but this is better ...
Cool.
Srinath.

[davipu]

you stink.  how's that for opinions.

[Blueknyt]

this coming from one who steals Turds?   kettle calling the pot black aint it?  


Srinath, i didnt form a lip its just a hole, but its alittle smaller in Diameter then the rubber flange on the Aircleaner, so instead of the K&N sliding over a lip, it plugs into the hole, i put a small dab of RTV on backside to help it stay, but i have a small rig im working on  that will just act like a snap spring like on the older float bowls that didnt uses screws. but lets see how the RTV holds it on.

once i cut the plexi to fit the slot in the airbox snugly leaving alittle overlap at the top, i heated the plexi up with a torch just enough to make it plyable, folded it to comform with the box and let it cool that way. ill snap a pic of it installed tomorrow and post it for you.