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DPDISXR4Ti

2003 Kodiak Air Filter Box Replacement / Modifications

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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???

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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.

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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.

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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.

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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.

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