Is this the stock ex250 airbox?

baz666 · March 23rd, 2014, 11:01 AM

The airbox on my recently purchased 2000 ex250 doesn't match the Kawasaki diagram fiche. Anybody know what bike this is from?

The airbox on my bike has a round hole at the top front, just above and behind the carbs. It's about 1/2" in diameter. The shiny stuff is silicone I used to seal the gap between the two halves of what is a warped old airbox.

http://www.flickr.com/photos/69874352@N00/13359365273/

http://www.flickr.com/photos/69874352@N00/13359206495/

http://www.flickr.com/photos/69874352@N00/13359594684/

And this hole is at the bottom right of the airbox, next to the big crankcase hose. This smaller hole seems to be a fuel overflow outlet and according to the diagram should have a hose attached, with a plug at the end of the hose.

http://www.flickr.com/photos/69874352@N00/13359365563/

Here's the link to the Ron Ayers diagram fiche of the ex250 airbox.
http://www.ronayers.com/Air-Cleaner-C391948.aspx

DaBlue1 · March 23rd, 2014, 11:34 AM

The airboxes on pre-gens look similar to yours, only thing is is that you don't have a full picture of yours to confirm it. My guess is your is just old like you said.

baz666 · March 23rd, 2014, 11:39 AM

Thanks for the awesome photos. That's my airbox.
I'm not familiar with these bikes. Mine is a 2000 ex250. When you say Pre-Gen, does that mean 86-07 bikes?
The Kawasaki parts fiche for the 2000 EX250 doesn't show that round protruding hole at the front of the airbox.
So there's no hose that attaches to that hole? Doesn't it allow unfiltered air into the airbox?
thanks again.

DaBlue1 · March 23rd, 2014, 11:50 AM

Quote:

Originally Posted by baz666

....When you say Pre-Gen, does that mean 86-07 bikes?

Yes

Quote:

Originally Posted by baz666

...So there's no hose that attaches to that hole? Doesn't it allow unfiltered air into the airbox?

That hole should not go all the way through. Check it.

choneofakind · March 23rd, 2014, 11:53 AM

For what it's worth, don't worry about that extra nipple at the front of your airbox.

Mine has never had anything attached to it and never will. It's not given me any problems.

baz666 · March 23rd, 2014, 12:58 PM

Okay, thanks for the tips.
Yep, that hole at the front doesn't go all the way through. Why it's there is a bit of a mystery to me. Maybe same basic design shared with another model and adapted as necessary.
So the airbox is correct, just in rough shape.
There was a 1/8" gap at the back of the airbox between the two halves. I got them to fit a bit better then sealed the gap with silicone. Same with the missing rubber gasket that seals the airbox cover at the rear of the airbox.

I'm hoping all this had something to do with the carbs getting too much air but I suspect I'll have to take the carbs off and give them a good clean. The bike sat for about a year not running so the pilots are likely clogged up.
Currently, it runs cleanly only on choke and is very sluggish off the throttle. I tried some Seafoam, new gas and new plugs and that helped a little but the bike doesn't have the snappy throttle response I felt when I rode one of these in SE Asia that was properly maintained.
I guess it's carb cleaning time.
thanks again.

March 23rd, 2014, 11:01 AM	#1
baz666 ninjette.org member Name: Baz Location: Takoma Park, MD Join Date: Jan 2014 Motorcycle(s): 2000 EX250 Ninja Posts: 59	Is this the stock ex250 airbox? The airbox on my recently purchased 2000 ex250 doesn't match the Kawasaki diagram fiche. Anybody know what bike this is from? The airbox on my bike has a round hole at the top front, just above and behind the carbs. It's about 1/2" in diameter. The shiny stuff is silicone I used to seal the gap between the two halves of what is a warped old airbox. http://www.flickr.com/photos/69874352@N00/13359365273/ http://www.flickr.com/photos/69874352@N00/13359206495/ http://www.flickr.com/photos/69874352@N00/13359594684/ And this hole is at the bottom right of the airbox, next to the big crankcase hose. This smaller hole seems to be a fuel overflow outlet and according to the diagram should have a hose attached, with a plug at the end of the hose. http://www.flickr.com/photos/69874352@N00/13359365563/ Here's the link to the Ron Ayers diagram fiche of the ex250 airbox. http://www.ronayers.com/Air-Cleaner-C391948.aspx

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March 23rd, 2014, 11:34 AM	#2
DaBlue1 Long Time Rider Name: Blue Location: Charlotte, NC Join Date: Sep 2010 Motorcycle(s): 2009 Kawasaki Ninja 250R Posts: A lot.	The airboxes on pre-gens look similar to yours, only thing is is that you don't have a full picture of yours to confirm it. My guess is your is just old like you said.

March 23rd, 2014, 11:39 AM	#3
baz666 ninjette.org member Name: Baz Location: Takoma Park, MD Join Date: Jan 2014 Motorcycle(s): 2000 EX250 Ninja Posts: 59	Thanks for the awesome photos. That's my airbox. I'm not familiar with these bikes. Mine is a 2000 ex250. When you say Pre-Gen, does that mean 86-07 bikes? The Kawasaki parts fiche for the 2000 EX250 doesn't show that round protruding hole at the front of the airbox. So there's no hose that attaches to that hole? Doesn't it allow unfiltered air into the airbox? thanks again.

March 23rd, 2014, 11:53 AM	#5
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	For what it's worth, don't worry about that extra nipple at the front of your airbox. Mine has never had anything attached to it and never will. It's not given me any problems.

March 23rd, 2014, 12:58 PM	#6
baz666 ninjette.org member Name: Baz Location: Takoma Park, MD Join Date: Jan 2014 Motorcycle(s): 2000 EX250 Ninja Posts: 59	Okay, thanks for the tips. Yep, that hole at the front doesn't go all the way through. Why it's there is a bit of a mystery to me. Maybe same basic design shared with another model and adapted as necessary. So the airbox is correct, just in rough shape. There was a 1/8" gap at the back of the airbox between the two halves. I got them to fit a bit better then sealed the gap with silicone. Same with the missing rubber gasket that seals the airbox cover at the rear of the airbox. I'm hoping all this had something to do with the carbs getting too much air but I suspect I'll have to take the carbs off and give them a good clean. The bike sat for about a year not running so the pilots are likely clogged up. Currently, it runs cleanly only on choke and is very sluggish off the throttle. I tried some Seafoam, new gas and new plugs and that helped a little but the bike doesn't have the snappy throttle response I felt when I rode one of these in SE Asia that was properly maintained. I guess it's carb cleaning time. thanks again.