I have a problem making the air boot fir real good on the back side of the carb on my 250r. The carb is a 38mm pj bored to 40mm and i can not get it to fit. I have heated it up and tried to make it expand a little it kinda works but it leaks and is making my jetting go weird and i would like to know how to fix. Is there a aftermarket air boot or some thing please help.

 

order a new OEM boot from Service Honda. they get brittle over time and are a beotch to get on. A new boot will be much more pliable and easier to work with.

 

I had the same problem, swapped to a 38mm air stryker and the stock air box boot is too small. I was eventually able to get it on and then I used a hose clamp and clamped it down tight, it hasn't budged since. One problem I had was my air box lid position was causing the air box boot to not fit square on the carb. I ended up modifying the rear mount point. I ended up securing the air box lid on the back to the underneath, not the top as it is suppose to be, it worked great and the carb fit perfect to the air box boot.

 

ive done it a couple of ways. boiling rubber to get it soft then putting it around top of bottle to stretch then hurry and get it installed. using flame from little butane torch was faster. both worked. barely. i have to remove carb to do this and install together.

 

alot of people who sell aftermarket airboxes liek my timmyboys or and esr airbox eliminator use a piece of hose about 4 inches long to connect to from the carb to the airbox.. i notoced that circumfrence of teh hose was larger than the carb.. i assume this was for a larger carb..