Custom Air Box for KZ440.

The stock box was falling apart so vs messing with pod filters, I thought I would make something to replace stock box.

The first box I made was out of a ABS plastic Radio Shack project box.


It was cheap & it worked fine for about 1000 miles till I noticed it was cracking all over the place.

So I started looking for something better & I found this cast aluminum box on amazon, CU-476-Aluminum-Econobox .







A 1.75" Hole saw was used to drill the holes for the carb boots & air filter.
I made a couple of brackets & bolted them to the cover of the box with M6 stainless bolts & lock nuts.
The 0.75" hole on top is for the crankcase breather tube.
The rubber piece on the front of the box is from 60mm pod filter.

I used a ABS fitting in between the filter & box to restrict the air flow down to match the stock box.



Here is the filter I'm using.




Overall it turned out better than expected & the bike runs great with it.

It looks nice too,
Pete

Things like this are the reason I check this site almost every day! That is awesome. Do you have any pictures of how it looks on the bike?

dom2570 wrote: Things like this are the reason I check this site almost every day! That is awesome. Do you have any pictures of how it looks on the bike?

Well done!!

Very nice! I will need to come up with something like this soon if I cannot repair the stock airbox that a PO shredded on my 78 KZ400.

Extremely well executed. I just restored and sold a low mileage 1979 kz400 LTD that had the stock airbox but no manifold rubber, filter or filter holder. Finding a replacement was nigh on impossible. Nothing on ebay and the couple of complete airbox units I sourced were being priced at gouge prices as the 400 LTD was unique to that one year. I fabbed a holder a filter and the results were satisfactory but not nearly as elegant as your fine work. Bravo!

peter1958 wrote: Well done!!

diggerdanh wrote: Very nice! I will need to come up with something like this soon if I cannot repair the stock airbox that a PO shredded on my 78 KZ400.

cafedallas wrote: Extremely well executed. I just restored and sold a low mileage 1979 kz400 LTD that had the stock airbox but no manifold rubber, filter or filter holder. Finding a replacement was nigh on impossible. Nothing on ebay and the couple of complete airbox units I sourced were being priced at gouge prices as the 400 LTD was unique to that one year. I fabbed a holder a filter and the results were satisfactory but not nearly as elegant as your fine work. Bravo!

Thanks!

dom2570 wrote: Things like this are the reason I check this site almost every day! That is awesome. Do you have any pictures of how it looks on the bike?

Thanks, here is a picture of the whole bike.


That stain on the ground is just from WD-40 not a leak.

That is one clean bike!

This is an awesome idea. I am planning to build one also. I tried building one with sheet metal, but I don't have any experience with sheet metal, and no access to welders, so it turned out terrible. Can you give more information on the ABS fitting that you used?

I don't know if he used the same fitting, but from the original topic over at the KawasakiMotorcycle.org site, the plumbing fitting used was an 1-1/2 ABS trap adapter fitting.

What fitting did you use to connect filter to airbox? And what did you use for the rubber boots that connect to carb? How did you seal everything? And is there anything in the box? I know it's an old thread but any more info would be awesome.