KZ440-A1 Air Filter Holder -- Fabrication Example

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15 Jun 2008 22:17 - 15 Jun 2008 22:25 #220261 by dnpurdy
So I picked up a 1980 KZ440-A1 LTD that lacked an air filter element or holder. Apparently this is a common problem. So, rather than endlessly trying to tune the carbs for pods, I fabricated new filter holder made of aluminum. I've included steps and plans to help anyone else who might have this issue.

#1: I purchased a 12"x12" sheet of aluminum from Home Depot. You will also need tin snips, some small rivets, 1/8" & 1/4" drill bit, and mounting bolts (2 M6x16)

#2: Here are two links to that are to scale plans for the box. just print it off without scaling and it should fit the box.

This first plan has a 3/8" pocket for filter element. This is good for fitting one layer of UNI foam element, or two oiled '000' synthetic scour pads I'm using until I get my UNI foam.
Plans for 3/8 holder

This second plan has a 3/4" pocket for filter element. This is good for fitting two layers of UNI foam element, say one black one red.
Plans for 3/4 holder

#3: The solid black lines are for cuts. The dotted lines are folds: all short dashed lines should be folded into the page and the one long dashed line folded the other way (out of the page).

I used a hammer over a sharp corner to fold the aluminum bends.

#4: I folded the tabs inside on each of the four corners and tucked them under. I then used a 1/8" drill bit to make the holes for the aluminum rivets.

#5: Three pilot holes were drilled with the 1/4" drill bit in the front face and the tin snips used to open the passages up.

#6: Lastly, the two mounting holes were drilled by placing the holder onto the airbox and locating the proper centers. The centers given on the diagrams are just approximate.

let me know what you guys think. I have some o-rings on order to arrive midweek - after that I can let you know how it operates. Below are some photos, including one with the holder mounted with two oiled scour pads in place.

[img size=(300)] www.davidpurdy.net/Holder/dscf0001.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0002.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0003.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0004.jpg [/img]
[img size=(300)] www.davidpurdy.net/Holder/dscf0005.jpg [/img]

(1980 KZ440-A1 sold project bike)
(1982 KZ750-N1 still stolen)
1982 KZ750-N1, my only now
Last edit: 15 Jun 2008 22:25 by dnpurdy.

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16 Jun 2008 15:02 #220373 by Biquetoast
Replied by Biquetoast on topic KZ440-A1 Air Filter Holder -- Fabrication Example
Wow man, nice work!
Very nice of you to contribute the patterns back.
B)

(1.) '75/'76 KZ400D - Commuter
(2.) '78 KZ750B3 Twin - Commuter
(3.) '78 KZ750B3 Twin - Commuter
(4.) '75 KZ400D - Sold
kz750twins.com

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17 Jun 2008 06:48 #220473 by wiredgeorge
Replied by wiredgeorge on topic KZ440-A1 Air Filter Holder -- Fabrication Example
Purdy... this is a most useful post for a KZ440 owner. I would get it to Stein for inclusion in the permanent filebase or tech article section. It will soon get lost here in the carbs section and given the poor search abilities of the forum, may not get into the hands of those that need it otherwise. Good job! wg

wiredgeorge Motorcycle Carburetors
Mico TX
www.wgcarbs.com
Too many bikes to list!

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17 Jun 2008 09:26 - 17 Jun 2008 09:43 #220497 by dnpurdy
I'll throw it together into one PDF file so that it is easier to keep in the filebase.

single PDF version

(1980 KZ440-A1 sold project bike)
(1982 KZ750-N1 still stolen)
1982 KZ750-N1, my only now
Last edit: 17 Jun 2008 09:43 by dnpurdy.

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10 Jan 2012 13:22 #497401 by jdouds94
This is awesome. ive been looking for something like this for a long time. I will have to try it out

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10 Jan 2012 15:08 #497411 by TeK9iNe
Nice work - However... Oiled scour pads...??? :blink:

Fo - get that shit mate. Get some real filtration in there pronto. Use a good car filter. You should be able to find one that fits right in there nicely/or jsut clip it - and wont cost much at all.
If it aint manufactured for air filtration use, dont use it, else you'll be rebuilding that engine in no-time.

2cents.

B)

Motorcycle Shop Owner/Operator

79 Kawie Z1000 LTD
81 Kawie Z1000 CSR
83 Honda VT750C A
85 Kawie GPZ900 A2
86 Zukie GS1150 EG
93 Yamie XV1100 E
Lucky to have rolled many old bikes through my doors ;)

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