Quantcast
Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

DPDISXR4Ti

2003 Kodiak Air Filter Box Replacement / Modifications

Recommended Posts

Am I missing something, or is the lower air-box all but impossible to replace once it's been removed? I guess in hindsight maybe I didn't need to remove it to get the carb out, but it's out now, and doesn't want to go back.

I'm considering cutting out an inch from the back and making it shorter, but obviously that won't be a quick task. Might be easier to just get an after-market filter and get rid of the box, but I really hadn't planned on that.

Suggestions???

Share this post


Link to post
Share on other sites


I have the same problem with the airbox on my LT-R, it won't come out or go back in without doing it exactly right. Like quadmaniac said, if it came out, it will go back in.

Share this post


Link to post
Share on other sites
If you got it out, it really should go back in. What's it hitting?

I really had to yank on it to get it out - it's hitting the back panel just forward of the battery. I almost got it in place, but then realized I had totally smashed the hose clamp down for the inlet hose.

Share this post


Link to post
Share on other sites


Have you gotten it in yet?

Nope. Thinking about cutting some of the front-to-back length out of it and plastic-welding it back together.

Share this post


Link to post
Share on other sites
Well, whatever you do, good luck with it. I hope you can get it back in there somehow.

Ironically enough, I was getting this done about the same time you posted this yesterday! I clipped the rear tang off the lower air-box - it doesn't even get fastened any way, so all it mostly does is gets in the way when re-installing.

The other "trick" was to pull the forward hose clamp back - the one that fastens the inlet hose to the carb. I did this since you have to have the hose attached to the air-box when installing, and you really have to mash the snot out of that hose as a result. Once you get everything positioned in place, you pull the hose clamp forward into place and tighten.

Glad I didn't have to cut it - hope I don't have to pull the box again any time soon.

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By jimsvtx
      I'm working on my brothers' 2002 Suzuki Vinson 500 . It sat for a few years before I got into it. I'm concentrating on the carb - I replaced orings, needle, etc. and soaked jets, bowl and anything that I could get off the carb that the solution wouldn't eat. I also removed the tank and flushed it with hot water - it's clean. The gas cap innards rusted away and the tank had a lot of rust and water in it before I cleaned it. I replaced the gas cap and installed a new fuel valve because the screens were broken in the old one. The bike will run but spits and sputters and backfires. If you "open it up" it falls on its face and stalls - but starts right up. Here is a link to an exploded view of the carb: Ohio Honda Yamaha Motorcycle ATV Dealer - J & J Motors - Kawasaki Suzuki Scooter Utility vehicle, parts, accessories, apparel
      Can anyone point me in the direction of the problem? It may still be a "clean carb parts issue" . My problem is that the parts list doesn't identify the parts to a degree that I understand. If you said" look at the pilot jet", I'm not sure which jet that would be....See what I mean? It'll run very good if I remove the air filter and cover the opening with my hand and part my fingers a little for the air to get in. Any help is greatly appreciated.
      Thanks in advance, Jim
    • By JacobSlabach
      got 7 atvs off CL recently for a good price.  one of which is a yamaha warrior.  anyone know where the vin is printed on this bike?  Haha good place to start as I do not know year or size yet.  The former owner says needs exhaust ans and clutch work.  he said it ran fine until the clutch cable broke and then I couldn't get the new cable adjusted right and it would grind gears.  things I see:  clutch cable locked up again, no brakes, carb leaking (green with algae around the bowl and has gelled gas stalagtights on it), aftermarket exhaust melted the airbox so I need something different and a new air box.  I would like the use the current exhaust if I can but I have a feeling its a redneck fix as it looks like there is an ace bandage holding it to the exhaust pipe (its an aftermarket slip-on exhaust), so I'm not sure about that- lets get the bike running first.  also, battery (looks brand new, what a shame) is dead, 0 volts.  Otherwise, bike looks to have not been wrecked, and plastics are ok (it sat outside under a 'tarp' for 3+ years since it was run last).  any tips and advise on where to start first would be awesome as this is my first clutched bike (manual).
      the clutch is my main concern- I've never rode a clutched bike so I dont even know what its supposed to feel like.  lol I'm spoiled on my automatic polaris 
    • By JacobSlabach
      recently picked up some project bikes off CL for cheap.  got a honda fourtrax (the ancient 4x4 kind with the straight axle in the front as well as the rear and a back-up kick-start)  plastics are crap, but my goal is to get running like a champ and patch the plastics up and sell to one of my many friends that want a reliable 4x4 for dirt cheap and doesnt care what it looks like.
      so the former owner says it needs carb rebuilt, but its sat for 3+ years since so who knows.  things I see:  carb is missing (he gave me a box of parts along with the bike), engine turns over and feels good with kick-start, brakes need work, battery missing (That always puts me off, cause then I know most likely someone's been tampering with the electrical.
    • By ray desocio
      I posted earlier looking for a wiring diagram, but maybe someone can help me with the problem if they’ve had it before. 
       
      The quad Will start and idle ok, when I open the throttle it will rev all the way up until WOT and then it dies back down to idle, and if I keep the throttle wide open it will rev back up. It will do this over and over and over. 
       
      I replaced the carb, (twice), Rectifier, battery, and spark plug.  The Stator ohmed out to the proper specs from dinli.  The other issue i can see is I’m not getting 12v on the choke circuit. The lights don’t work either. 
       
      possible bad key switch? Maybe the new rectifier is bad? All the contacts on the key switch also ohm out properly    
      comprsssion is up to 125 psi and spark is there. 
       
      Reed valves look great.....
       
      im at a loss. Any trouble shooting advice would be appreciated. 
  • Similar Tagged Content

    • Guest
      By Guest
      Ok...I'm gettin' me juevos ready to do an oir filter clean....
      Went to my local harley/quad dealer and he had me purchase the No-Toil kit (Cleaner, Air Filter Oil, Rim Grease)
      What I've read is that the No-Toil cleaner will NOT clean
      other oils off air filters....just the No-Toil oil....
      So, I've also read that others have cleaned their air filters
      in the kitchen sink, used gasoline, or used flash solvent....
      Looking for advice as I've mentioned I'm very mechanically
      DECLINED!
      I'm going to wash the air box seal in the sink and give it a good dry....
      One more thing......No-Toil or Bel-Ray for filter oil?
      Thanks!
      -TD
    • By Chayse Hill
      I have a 2003 LTZ 400 that i bought a few days ago. The quad was running fine until last night. I let my brother ride it down the street and back and i didnt notice anything etong with bike. Then my neighbors friend came over and said "can i ride it?" I said "sure" so he ripped it down the road all fine and when he got back it died right in front of us. My brother said it was dieing on him also. He also said that he wasnt using the clutch to shift. I told him he was an idiot. Im throwing that in there incase that caused a problem as well. But today i go to check it to make sure its getting fuel which it is and replaced the spark plug incase it wasnt getting spark but it is. So i started it and it was having a problem starting then i got started and was reving at idle high. So i took it around the block and it died on me a little bit down, so i try to restart it and it started so i kicked it into 1st and it kinda launched on me and started going with the clutch all the way in. Then it died right after and wasnt running right during that process and was idleing all over the place and just died and now i cant get it started it again. Before it would start without the choke or priming it. It would start real quick now i cant figure if it needs to be rejetted or something else. Air filter looks clean also. But any help would be gratelly appreciated!
    • By crazynordlander
      Hi All,
      Has anyone found engine oil in their air filter box. The must be little or no baffle between crankcase ventilation and that hose that attaches to the air filter box.
      I went to pick up my ATV today 60 miles away that they could not fix the jerky low speeds on and before I loaded it decided to check on this. Sure enough there was a good coating of oil with some pooling in the bottom of the air filter box. The air filter has oil on it too but is it a dry element or oiled element type. My guess from the color of it dry.
      I heard on a comment on my YT videos that there is a kit for this issue? Is this a CFMOTO fix?
      Thanks
      Kevin
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...