KZ550 Airbox install (with engine installed!)

[danmaloy]

Picked up an 82 KZ550 LTD with pod filters on it...needless to say it runs like ***...want to get a stock airbox...but not sure the airbox will fit in the frame with the engine in place? I can (easily) remove the carbs, but still not sure (since I don't have the part!) if the airbox will clear the engine and slide between the frame rails?

I'm about to buy an airbox on ebay (in about 4 hours!)...and hoping someone out there might know the answer to this question.

NOTE: I've also found out there are two types of airboxes (if not 3; looking at the gpz stuff) for the 82 KX550...it appears mine is the one that does NOT seperate in half...which is why I'm concerned it won't fit with the engine in the frame.

Thanks in advance for any answers (or guesses!).

Dan

[StarGate]

All the ones I've seen could be fitted with the engine in but required the carbs to be off. Theres always those few that won't fit those situations but none that I'm currently aware of.

[danmaloy]

Thanks Mike...

That's what I was hoping to hear!

I have the carbs out now and there looks to be enough room...but I only having the airbox that separates in the middle (aka, not the right one!) so it's hard for me to judge if the one piece airbox will fit...basically the last "project" I want to get into is dropping the engine so I can squeeze the airbox into the frame! Well I guess my other space saver would be to remove the carb intakes...

...but I'm going with it will fit! Now to find one AND get decent airbox intakes (rubber pieces between airbox and carbs)...

[StarGate]

Check with Z1enterprises.com they carry those for a lot of the older models and they have good prices.

[vinnye]

You should be fine.
I have done Z750 and ZL1000 airbox and carb reoval and installation - but not a 55o. But dont think there will be any major differences in method.
If you can find some new intake rubbers that will definitely help. If the old ones are hardened - it will be a LOT HARDER.!
I would suggest, since you have the carbs off, manouvre the airbox into the space, but do not fasten the bolts up. Allow the airbox to sit in place but with the bolts loose, you should be able to wiggle a bit more room!
Attach the intake rubbers to the airbox (be careful, they are usually in 2 pairs, for the different carbs!). Some people fold the intake rubbers back and hold them in that position with a Tie wrap or Jubilee Clip etc.
Also. a thin piece of plastic can be used to help slide the carb rack past the inlet manifold stubs.
Line the carbs up with the inlet stubs, and by pushing the carb rack down and then in, slide them onto the stubs. (A little engins oil on the rubbers may help here!). Be careful these stubs can be damaged fairly easily!
When the rack is in - do not fasten the clips yet.
If you tied the intake rubbers up, loosen the middles two and flip them over the carbs. The do the outer two.
Now you can button everything up

I used a tool like this, to aid in flipping the rubberss. It is made from a briclayers metal tie - with one end straightenewd and trimmed off.

[danmaloy]

Hey Guys...great info and tips/tricks on getting this bike right!

I missed out on the airbox on eBay this weekend...so I put my carbs back on the bike and duct taped the pod air filters mostly closed...and man what a difference! While I KNOW I could easily tune this bike to run with the pods, the bike is for my girl...who I know will more than likely get caught in a rain shower (or two)...plus then I don't have to come up with a crankcase breather and same with the valve cover breather(s)...these things are like old timexs!!

So now I'm on the hunt for a quality used airbox and rubber intake/runners (from airbox to carbs). If anyone has one; or knows of one for sale for a '82 KZ550 LTD I'd certainly like to know about it! I have been checking out the Z1Enterprise.com and don't see any airboxes (except KZ1000) or intake boots available for the 550...any other leads/suggestions?

Thanks!

Dan

PS Also I'veHey Guys...great info and tips/tricks on getting this bike right!

I missed out on the airbox on eBay this weekend...so I put my carbs back on the bike and duct taped the pod air filters mostly closed...and man what a difference! While I KNOW I could easily tune this bike to run with the pods, the bike is for my girl...who I know will more than likely get caught in a rain shower (or two)...plus then I don't have to come up with a crankcase breather and same with the valve cover breather(s).

So now on the hunt for a quality used airbox and rubber intake/runners (from airbox to carbs). If anyone has one, or knows of an 82 KZ550 LTD airbox I'd certainly like to know about it! I have been checking out the Z1Enterprise.com and don't see any intake boots are sold there...any other leads/suggestions?

Thanks!

Dan

[StarGate]

If you can't find it on Z1's website, give them a call. They have some stuff that isn't listed on the site and if they don't have it they can get it some times. They have gotten stuff for me that way that they didn't normally carry. I'm referring to the rubbers not the airbox.