400/440 Air Box Top Search

I was doing some reading in here about what parts I might need for my '79 KZ400 LTD, and I saw a thread about the unavailability of the air box top, or "Cap, Air Cleaner, 11012-1086."  I figured that since this part is so hard to find, previous owners for some reason either took it out or left it out when they did whatever repairs they were doing. I've only seen this part mentioned (so far) for the KZ440, but I assume it also goes in the 400 LTD as well...?  How important is this part, what impact does it have on the bike's performance, and what can you do if it's not available? Is there a work-around for it?

As you can see in the list I linked to below, that part fits the KZ400H-1 and a whole herd of KZ440 models. Since it is the part that the actual filter goes into, I suspect it is really important.

www.partzilla.com/product/kawasaki/11012...fdad6bcc6410e084087d

Another reason for the missing airbox cap is that it tends to break then gets tossed. or gets tossed when guys try pod filters.

Someone on EB is selling a new part made from ABS plastic. I assume it's 3D printed. not sure. Pricy, though.
Kawasaki Kz 440 airbox cap replacement kit Part# 11012-1086 >> Item # 274796504333

Yes, I see that, and I agree - methinks he knows what it is, and its importance. A seller's market, as it were...I never understood pods, besides being easier to replace. I love how people think they know better than the engineers who designed it. It's a lot like the #2 idler gear on a Yamaha Virago - tons of 'fixes' online, yet they only perform half as well.

Anyway, so is there a work-around/suitable substitute, or does the lack of this 'cover' condemn 400's/440's to a life as a pretty paperweight? 

 

Here's a topic in which someone here on KZR made an airbox w a pod filter.  scroll down for the pics on pg 2.
kzrider.com/forum/3-carburetor/599569-cu...x-for-kz440?start=12

I haven't read the whole thing & only bits today, but the op tried an ABS box but it didn't hold up to the vibrations n stuff.
So guy on page 2 made something similar from an aluminum box but it was a bit of work to make it fit.
The homemade jobbie acts as an extender for the pod filter & its purpose was to stabilize the airflow. 


 

wrote:

Another reason for the missing airbox cap is that it tends to break then gets tossed. or gets tossed when guys try pod filters.

Someone on EB is selling a new part made from ABS plastic. I assume it's 3D printed. not sure. Pricy, though.
Kawasaki Kz 440 airbox cap replacement kit Part# 11012-1086 >> Item # 274796504333

Pricey, Yes but it also includes the filter. I'm thankful people are out there reproducing these parts. There's also a used one on eBay for a little less. My process is an automated daily search on eBay for the factory part number until I get a hit on the part I want at a price I'm willing to pay. Takes years sometimes but that is the life we have chosen 

Thanks.  The kit also includes the air filter case, so you get 3 parts.  considering how much trouble it would be to make something, sometimes you may as well go ahead & pay. 

ps:  same as the original airbox cap, don't over-tighten the screws. 

martin_csr, thanks for the thread! Looks like it would be interesting and fun to build - and Yes, I saw that Ebay repro one, and I have to admit it looks really good...has anybody here bought one?

FWIW, Hawk Electronics has the same box for $11.30 rather than the $20 Amazon wants...
CU-476 BUD Enclosures | Hawk Electronics (hawkusa.com)