Custom Air Box for KZ440.

Most folks who ditch the stock air filter box put a small filter on the crankcase vent. The only problem you may encounter is an oily film on that part of the engine. Another alternative is to run a long hose from the vent to the rear of the bike. Little if any oil mist will travel that far. At least one guy here routed the hose to drip on the drive chain.

Does anyone know if the rubber boots were the inlet duct 1,4 part # 11015-063 or inlet duct 2,3 part # 11015-057? Also when installing these into the box, how well do they fit? It seems like they could move in and out, or is there a securing mechanism I didn't see?
At least from what I saw, you just cut a hole and fit the smaller end of the boot in and that's all (?)

Also, what is the tube at the top??
Thanks :]

newkzrider18 wrote:
Also, what is the tube at the top??

The tube is for the engine vent and is connectet to the valve cover.

Hi all,
fascinated by this mod for my KZ440 LTD & had a go yesterday, unfortunately I can't seem to get the box to go high enough as the frame stops it (only by about 1/4" or so), if the box is any smaller I wouldn't be able to fit the boots properly? (that's why there's a nice angle on the original box.....).
Have been looking at possible ways of being able to move the box back by maybe 1/2", like fitting a flange.......?

Anyone else have any ideas?
cheers
Roy

RoyB wrote:

Hi all,
fascinated by this mod for my KZ440 LTD & had a go yesterday, unfortunately I can't seem to get the box to go high enough as the frame stops it (only by about 1/4" or so), if the box is any smaller I wouldn't be able to fit the boots properly? (that's why there's a nice angle on the original box.....).
Have been looking at possible ways of being able to move the box back by maybe 1/2", like fitting a flange.......?

Anyone else have any ideas?
cheers
Roy

Look at second page, third post down...are your airbox holes similar to what is in the pics, up near the top?  Also, the airbox boots have a slight angle...if you have them angled the wrong way I can definitely see it making the box shift upwards.

I took inspiration from this thread and designed a 3d printed an airbox.  If anyone wants to make one, the file is here:  cad.onshape.com/documents/90529535924d74...1e1da65dfb476e2aa3d9

i used a 2" fernco ($6 at the hardware store), cut in half as the boots.  You can either rough up the fernco (flexible PVC) and use superglue, or just use a second gear clamp- i tried both and they both work well.
$20 of plastic sure beats buying an airbox that's older than me of ebay for $100s...

this thread took my un-useable new (to me) bike and made it run perfectly (as best i can tell, its my first bike).  I did increase the pilot jets to #38's before replacing the pods with this intake, and have them still fattened up.  I put an O2 sensor on the bike, so i have an OK idea I'm running well thru the ranges despite my complete lack of experience with motorcycles or carbs in general.

Thanks for everyones input in this forum, you've collectively saved my tons of time and money.

-Michael.

That looks very clean nice work in my opinion but what do I know?