Well, my dealer called me this morning to let me know that my airbox had finally come in. It seems that while high centered on a stump, I managed to break a large hole in the bottom of the old one, which allowed all kinds of mud and water to enter the main box compartment. The new airbox cost me $27.23, which was his cost, so that wasn't bad at all. It comes as a complete airbox unit, with upper rubber seal and heat shield. It DOES NOT come with with the water drain plug, or the other plug for the lower part of the front of the box.

For those of you who don't know, the airbox actually consists of three separate compartments. The first being the main housing in which your actuall air filter sets in. The second part is the water drain box, which is a kind of reservoir to let water out of the airbox through the bottom, but prevent it from coming back in. Now, the third compartment is one that I had not noticed before, which actually runs the height of the airbox in the very front of the unit. It has a nipple at the lower end which is capped off. This compartment bypasses the air filter, and runs strait up the hose to the carbuerator. I had broken mine off entirely, and wasn't smart enough to check the thing out. As a result, I had a bunch of dirt up my main air hose to the carbuerator. Hopefully I got it all cleaned out before anything major would have gone wrong.

Anyway, the new unit does not come with the cap required to seal off this nipple. If not capped off, water, mud, dirt and other debris can easily be sucked strait up into the carbuerator and enter the motor, which would then become bad news. So, seeing as how this is a part that the dealer normally doesn't stock, and would have to be ordered in, I had to look elsewhere to find a suitable replacement. I ended up with a Faultless brand Floor Protection leg tip-the kind you would put on the bottom of chair legs to keep from scratching your wifes brand new kitchen floor-in 1/2" size. They were a perfect snug fit, though I did put a hose clamp on just for added security. They come in a pack of 4 for around $1.99 or so.

Actuall replacement was fairly easy, with the hardest part ending up to be getting the airhose back on the new airbox. It's got the main hose that runs on the inside of the opening, with an outter shell covering that wraps around the outside of the airbox opening. Time to do the job is around 20 minutes or so at a leisure pace.

Anyway, sorry to be so lengthy on such a boring topic, just thought maybe somebody might be able to use the info.

Mike

 

Yeah, I pulled my airbox off once and remember the time I had trying to get the main hose between the carb and airbox, back on the airbox. I was trying to get it back together while the hose was still connected to the carb and that was almost impossible. I had to disconnect the hose from the carb, sit in a chair with the airbox between my knees and work the hose onto the airbox. That turned out to be pretty easy doing it that way.

 

I had to do this today also. The_Law got him a new carb and put it on with out all the parts(they didn't ship him all the parts) and we ended up haveing to put his stock carb back on so he could ride.

It was VERY easy when Matt decided to pass in the boot in threw the air box carb in first, it made it very easy.