Airbox ducts

Amasomeday91 · August 7th, 2023, 10:39 AM

Mechanically inclined friends. Got the boots that go from the airbox to the carburetor and can't get them seated in the airbox for the life of me. They are "OEM" as in not actually OEM but theoretically the same size as the original equipment. Any tip/trick I'm missing? Maybe they're just the wrong size? Maybe wrong material and not stiff enough? Everytime I get 40-50% seated correctly and try to force the rest it all just shoves through into the airbox. 🧐

Triple Jim · August 7th, 2023, 10:58 AM

I did the airbox separation mod, so I can put the boots on, clamp them in place, then move the airbox forward and connect it.

https://faq.ninja250.org/wiki/Batter...r_carb_removal

DannoXYZ · August 11th, 2023, 10:16 AM

Don't force things, make sure everything is lined up optimally at each and every step.

Clamp carbs-to-head rubber manifolds 1st so carbs don't move.
Then gently shove airbox towards carbs.

Reach in with long screwdriver and slide around rim of rubber boot to make sure it's overlapping on outside of carb all way around. If rim of boot is butted up to edge of carb, it won't go on and gets pushed into airbox.

Once boots confirmed overlapping carbs only on outside, then shove rest way on. Done!

Wouldn't hurt to lube outside of carbs with light layer of rubber grease.

eltel · October 11th, 2023, 05:11 AM

I just did mine with genuine Kawasaki parts. It is a bit tricky alright but I just covered the groove in a diluted washing up liquid and worked it in. Getting your fingers inside helps to smooth it internally. I did remove the airbox to do it though which made it easier. (carbs were being rebuilt so the entire rear mudguard was off, battery off etc).

August 7th, 2023, 10:58 AM	#2
Triple Jim Guy Who Enjoys Riding Name: Jim Location: North Carolina Join Date: Jul 2016 Motorcycle(s): Ninja 250 Posts: A lot. MOTM - Oct '18, Aug '17, Aug '16	I did the airbox separation mod, so I can put the boots on, clamp them in place, then move the airbox forward and connect it. https://faq.ninja250.org/wiki/Batter...r_carb_removal
	1 out of 1 members found this post helpful.

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August 11th, 2023, 10:16 AM	#3
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Don't force things, make sure everything is lined up optimally at each and every step. Clamp carbs-to-head rubber manifolds 1st so carbs don't move. Then gently shove airbox towards carbs. Reach in with long screwdriver and slide around rim of rubber boot to make sure it's overlapping on outside of carb all way around. If rim of boot is butted up to edge of carb, it won't go on and gets pushed into airbox. Once boots confirmed overlapping carbs only on outside, then shove rest way on. Done! Wouldn't hurt to lube outside of carbs with light layer of rubber grease.

October 11th, 2023, 05:11 AM	#4
eltel ninjette.org member Name: Tev Location: Ireland Join Date: Aug 2022 Motorcycle(s): 2004 E250 Posts: 18	I just did mine with genuine Kawasaki parts. It is a bit tricky alright but I just covered the groove in a diluted washing up liquid and worked it in. Getting your fingers inside helps to smooth it internally. I did remove the airbox to do it though which made it easier. (carbs were being rebuilt so the entire rear mudguard was off, battery off etc).