KZ200 air filter

Hey guys, my KZ200 project is coming together. Not really on schedule, as parts sellers have let me down a couple of times. But the engine is back in the frame, and carb is ready to go back.

I have a question about air filters for this bike. The bike has the original air filter box. This box stores a manky old air filter, 5 inches in diameter. I would like to replace it. When I search online, there are lots of foam, cone, pod, all types of filter for sale, advertised as for this simple single cylinder bike. However, none of them are the original spec. The original air filter was Kawasaki part number 11013-059. When I look up this part, a few come up for sale as NOS, but they look like grubby old junk.

The air filter box goes together like this:
www.kawasaki.com/Parts/PartsDiagram/141821/1978/KZ200-A1A

I was wondering, do you think it might be possible to get a standard, modern air filter, and rig it so that it's inside the air box? Seems a shame to dispose of an intact air box, which must be getting rare these days.
Or should I just remove the air box, keep it to one side and fit a pod/cone?

You might be able to refurbish the old air filter. Assuming yours has the metal mesh, the easiest way would be to remove the old filter media then install automotive foam filter, cut to size & glued in place. I have seen where some guys have used the paper media, but that's probably more work.

I would measure the old filter inside and outside diameter, height, etc and see if I could find one similar in size

wixfilters.com/Lookup/FilterBySize.aspx

martin_csr wrote: You might be able to refurbish the old air filter. Assuming yours has the metal mesh, the easiest way would be to remove the old filter media then install automotive foam filter, cut to size & glued in place. I have seen where some guys have used the paper media, but that's probably more work.

On Amazon I picked up a sheet of UNI foam filter material; it's 12" x 24" and 3/8" thick. Part of it will be used to make inserts for velocity stacks but the rest will be used to refurb an unobtainable* air filter for an old Yamaha.

* unless I want to pay $170

Thanks guys. Good suggestions there.
I've got a few more jobs to do on the bike, and am at the mercy of parts sellers as to when these bits and pieces arrive, so what I think I'll probably end up doing is stuffing the appropriate foam into the old filter housing. But I'd like to hear it running again soon (as I had the sides of the engine open), so I might just stick a pod on it as a temporary measure in the meantime to check all is well. Also that the electrics are good, etc.

Hello Pagala
Concerning your dilemma with an air filter replacement, have you conceded modifying the air box to except a different filter.
I have owned a Z200 for ten years and I have had the same problem as you obtaining good air filters.
In desperation I modified my air box to except an air filter from a Kawasaki KH125.
The modification is to remove the four prongs on the air box and air box cover and remove 1cm (¼ inch) or so of plastic from the threaded bar or bolt which holds the wing nut to secure the cover.
I used a sharp carpenters chisel to remove the plastic prongs and the plastic from around the threaded bar.
I have been running the bike for a year and had no problems with it.
There are some pictures of before and after.

Thanks Peter. Just saw your post, so apologies for the late response.

What I've got is the old filter's housing. It's a robust item made of metal, with a wire mesh inner circle. I've ripped out the paper from it, and have ordered some automotive foam filter material, and when this arrive I will cut a strip from it and glue it to the filter housing. This should work without having to modify the filter box. I did order a pod filter, but the very day it arrived I saw that it was rubbish, and so I returned it.

I'm not really up for keeping the bike all original - I rather prefer what the Indonesians are doing with their "Binter Merzy" (that's what they called their Z200s). Lots of interesting modified bikes on Youtube. So I don't object to modifying the filter housing, but for now I won't be doing that. I want as little of modern Chinese manufacturing as possible on this bike though.

I bought a NOS air cleaner for my kz305. The metal was a little aged looking. The ring of sealing foam seemed a little stiff. the paper element was fine. I installed it and all is well.