350X Air Box Fitment Issues

[bkm]

I put my air box, carb, and tubes on my bike the other day. It seems as if something has shrunk because everything is about a half an inch from going together. If you put the carb on first, then the air tubes, then try and hook the box up its to short. So the only way to get everything clamped down is to pull the carb out of its boot a little bit and then clamp everything down.

Has any else ran into tis problem. I have tried 3 different box to carb tubes and it's a little better with one but its still a pain in the butt to get everything clamped down.

[Mosh]

I have seen this a ton on 350x's. Here are a few options, as they will fall of while riding if you dont correct it now, and suck dirt in the engine.

1)Boil the airbox boot in Murphy's oil soap and water mixture just long enough to get the rubber soft. Remove the boot with utensils, and wear good oven mits (it will be hot) and stretch the boot length ways while it is warm and plyable and hold till it cools some. You may have to repeat this process a few times. And you made need a helper to hold the boot with you.
2) Sometimes you can also heat the airbox at the front and reshape it towards the frame and carb as they tend to warp inwards over the years. A heat gun or good hair dryer will work, wear gloves again.Use some boards cut to length to jam in the box while it is hot and hold it apart from end to end and let it cool that way for a few hours. You may have to repaet this process a time or two to get it to take shape.
3) Sometimes you can slot the air box mounts to slide it forward a little.

Generally a 1/4 inch is all you need to gain to get a good fit on each part. It won't take much. Just be careful with the boiling water method, and use the oil soap. It gets in the rubber and adds some flexing properties to the old stiff boot.
Doing those 3 things should make up that half inch for you.

[atc007]

Now THAT"S some good advice! Never heard that one,last few I built I had the option of buying a new tube. It is as common as worn axle bearings,they all do it.. Good luck BKM,we're waiting for pics!

[bkm]

Mosh, thanks a million man. That is a great tip. I was sitting there beating my head against the wall thinking how in the hell am I going to make this boot longer or if I could find a new oem. I know the boot had to have shrunk, that is the only explanation. I'll try that on Monday and report back.

atc007: Ill have some updated pics on Monday Or Tuesday. It will have all, the wiring, airbox and carb, rear brakes, ect. Once my forks get here it will be down hill from there.

[atc007]

I wonder how aggressive we can get stretching these? Guess trial and error! Can't wait to try it.

[Dirtcrasher]

All else fails, they are only welded on top. You can cut them and move them wherever......

Another option is to lop off the nub sticking out, build your own aluminum threaded collar (I could make them, any lathe can) that the rubber sits on and into the frame side "U's" (I think i'ts more like plastic, I forget); But, that wouldn't need welding of any sort......

[bkm]

Boiled it in some water and Murphy's oil soap and it fit. It is still a hair shorter than I wanted but it is completely snug at all points. I just pulled the front of the box out a little and it went right on nice and tight. Another plus is the house smells nice after boiling the soap. Thanks again Mosh and everyone for the idea's.