1980 airbox on 81

Hey everyone.
I'm trying to put an airbox back on my 1981 kz550. The previous owner converted it to pods without rejetting the carbs and I dont want to deal with the hassle of rejetting. I bought an airbox on ebay that belonged to a 1980 kz550. Im having a hell of a time getting it onto the carbs. Does anyone know if the 1980 airbox will fit on an 81?
Thanks
Nick

According to Kawasaki.com the following bikes use the same airbox:

KZ550-A1 (1980)
KZ550-A2 (1981)
KZ550-A3 (1982)
KZ550-C1 (LTD) (1980)
KZ550-C2 (LTD) (1981)
KZ550-C3 (LTD) (1982)
KZ550-C4 (LTD) (1983)
KZ550-D1 (GPz) (1981)

Ed

Thanks a lot. I must be trying to install them wrong

I know on the KZ650 it's a real tight fit (and impossible without removing the carbs). I only removed and installed mine once and it required a lot of patience and a couple beers. Ed

carbs have to be out and twist and turn every which way on mine and dont forget the brackets to hold it up :evil:

Contact Cleaner is your friend when dealing with air boxes.

I had an extra 1981 KZ 550 air box around here Ill look and see if it is still here.

On my 77 there are 2 straight boots and 2 angled boots the angled boots are on the outside. Note if your boots are hard or brittle stop now and get new boots or stop reading here as I can do nothing to help you. With the carbs out ... fold the boots over on themselves where they go onto the carbs. They will do it. It shortens the boots about an inch. Then place the boots onto the airbox and use the indexing knotches on the box with the cutout on the boots to see that they are positioned correctly. It is now pretty easy to put the carbs in place with the extra room. Hook up the cables now. Now unfold the boots over the carbs and voilar! Clamps and Bob's your uncle! Hope that helped.
I do not look forward to removing carbs or installing them but they are not a nightmare either. I was taught this by my father and my uncle and it is the best way by far. I'm pretty good at it too with about 5 minutes from go to end and no cursing or throwing things. Much luck with yours!

Thanks proxy. I had to end up getting new boots because the ones that came with the air box on ebay were the originals that were over 30 years old. They should be coming in the mail today and ill give that a shot.

Just got around to putting the new boots on. I rolled them over each other but still not enough clearance to put the carbs on. Are there any other tricks to doing this?

Push the rubber back into the air box.

Be sure to loosen the 2 little brackets at the back of the airbox. It will let you move it toward the back of the bike just a little, but every little bit helps. Ed