Maintenance & Technical > KX500 Original

Carburetor to airbox boot

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hangtime:
Howdy everyone,
Could someone help me out with some dimensions please? I would like to know the size of the flange where the carb boot meets the air box. And the distance from the bottom of the airbox flange to the bottom of the flange that attatches to the carb, I guess you could call it the offset on the horizontal axis. And last, the distance from carb end to the airbox end or overall length. The boot for the kx450f isn't even close, so I'm hoping I can make a new mounting surface on the airbox and run the KX500 boot between the two. From what I can tell on the Kawasaki microfiche the 500 mounting surface is smaller than the 450, this is better than too big.

Thanks

demographic:
I am not exactly sure what your asking so have taken some pics to clear up what I am measuring, if I can help I will.

hangtime:
Thanks Demographic,
I'm glad someone finally put this post out of it's misery. Those pics are exactly what I needed. I attatched some pics of my own. The pic of the cut frame was a nervous one, that is why I call it the "point of no return". The airbox pic shows how the 450f boot wasn't even close. With a KX500 boot being a smaller diameter than the 450f I'll be able to make an adapter plate that will cover the original opening and allow for the 500 boot and filter. If you're ever around California central coast you can take it out for a day.

demographic:
Ahhhh, good stuff :-D

So you kept the 450 airbox with the biger hole in it, made up a blanking plate to fit the smaller carb boot off the 500.

Keep those pics coming as it's an interesting project.

Have you seen this page with pictures of Service Hondas?
theres some pics of the Y piece that it looks like you need to build to get round the exhaust.

http://www.clubphoto.com/perl/app.pl/albums/large_image_view?id=2429935&link_code=sa01_17

hangtime:
Good link,

Man there are some spendy bikes there. I think I will try to machine two pieces of billet to slip inside each lower frame tubes, then machine a bend in them to meet the downtube, and maybe box the end of the downtube for some extra added strength.
I don't know if it would be any easier to get some square stock tube bent. If you notice the two lower frame tubes are not square to the frame or each other. They actually have a twist to them.
The good news is the cases fit perfectly between the swingarm. All I did was drill out the cases for a larger swingarm bolt (15mm vs. 17mm).

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