I have a 96 sportsman 500. The studs on the box are breaking out. I tried to epoxy and also JB weld but both let go after a couple of months. Any ideas> I was thinking of drilling the stud platform and maybe using carriage bolts maybe even using a washer from the under side?

 

That was a common problem on the old ones but I'm not sure how to fix it. Some have used a new air box but I think you have to change things to fit it.

 

I hated this air box on a daily basis. Lid has to be sealed tight or they won't run right.Epoxy doesn't hold the studs and a new box is over 70 bucks for the box and studs alone. In 99 they changed to a better air box design,but to change over to the new style would be costly. Have to decide on replacing the box or adding up the cost on the parts for the new system.

 

Seeing both of the boxes like that it looks like it involves changing even more parts than I thought.

 

Close as I could come up with the cost of the major parts not counting the small stuff was over 220 bucks on the new one. May be worth it to some people,others just replaced the box. I didn't even like replacing boxes alone,(changed out several) as everything had to be transferred over plus you knew eventually the studs would pull out again.

 

While it definitely is not the correct way to do it, I have the same issue. I sealed over the stud holes and used a thin, strong rope to tie the lid down as best as possible. I seems to do OK until I am able to figure a better, easier way to keep it sealed, but serviceable.

 

A bungee cord instead or a rope could keep constant pressure on it. I'm trying to think of a way to put clamps on it but not really coming up with anything good. I was sure happy to see the old air boxes go. It only takes a few seconds to fasten or unfasten the lid on the newer ones like my '08.

 

40 bucks for a good used 2001 box and lid might be worth the effort.Plus plenty of used minor box parts if needed.If I had an old 99 box that'd be the way I'd go to get rid of it. You can always adapt to fit the BST34 carb on the 96 Sportsman if need be.https://www.ebay.com/itm/01-POLARIS-...9aLdkA&vxp=mtr

 

So the 99-04 had a new design that would be compatible with 98 and older? Is it just remove old and install new or a lot more to it that that? Same filter on both?

 

Will be a little mods you have to do such as drill holes in the frame for the box mounting tabs,possibly may have to adapt the later model carb inlet duct to fit your carb,plus on some you may have to angle cut the air inlet duct a little more where it meets the tank so when you place your weight on the seat it wont block off air supply.We even had to do that on some 325 Trail Boss and Magnum models(that used the same box) when owners couldn't figure out why they would die on them.They ran good if you took your weight off the seat.. Shouldn't be a big deal as others have done it to get away from these older faulty air boxes. Same air filter used on all. Plus an old 30 buck Magnum 325 air box would probably work also as it's the same box. Just have to adapt to the carb and possibly hack some off the air duct if it interferes with the tank.https://www.ebay.com/itm/2000-Polari...5aCjNB&vxp=mtr