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another dumb airbox mod.question

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what did you use to cut out your airbox? did you remove the airbox to prevent filings,etc.from getting into the carb.,or just plug up the hole & cut away?i know it's a dumb ace question,but i figure you guys now best.thanks.

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I used a Dremel Moto-tool with a cutoff wheel. Did not remove the box, just stuck the vacuum hose in when I was done. I my case, there was very little mess, all the "cuttings" remained attached to the box, due to the heat of the cutoff wheel. 😢

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Roto zip would be perfect. Dremel will work, or a sawzall or jig saw. I used a combination of a hole saw and my diegrinder with a carbide rotory file. Cuts real easy and is even esier to clean up.

I did a bit more then the recomended. The more the better.

http://mutualwave.com/images/WJS/100_0037.JPG

This way I can mount my CDI in the factory location for vibration control, and still get good air past it.

http://mutualwave.com/images/WJS/100_0042.JPG

😢

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Roto zip would be perfect. Dremel will work, or a sawzall or jig saw. I used a combination of a hole saw and my diegrinder with a carbide rotory file. Cuts real easy and is even esier to clean up.

I did a bit more then the recomended. The more the better.

http://mutualwave.com/images/WJS/100_0037.JPG

This way I can mount my CDI in the factory location for vibration control, and still get good air past it.

http://mutualwave.com/images/WJS/100_0042.JPG

😢

MutualBill- do u run a pre-filter on that K&N? I've been using them in my trucks for years without issue but had a reasonabley competent mechanic tell me they allow significant particulate matter thru without the prefilter. Further if you have to use a pre-filter does that negate the airflow gains from the filter?

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No prefilter. I do not run in dusty conditions much. The only thing that could get through it would be extremly fine dust. If you ride in those conditions, you will want a foam filter...and to clean it alot.

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If do this mod can i still us the stock jetting?

Haven't been that deep into the bike yet. Kind of scares me.

NOPE, no improvement gained if you don't rejet, possible LOSS... get a 140 main and 25 pilot and an extended mixture screw for easier adjusting. Do a search and find Burned's recipe, follow it to the letter, and you will be thrilled with the improvement. 😢

Don't be scared to LEARN by doing. I can proudly say that NO ONE BUT ME has ever laid a hand on my KLX 400SR. This was my first carb mod that I did myself, I've changed sprockets, bars, modded all kinds of stuff, and the list goes on and on. There is always help here on TT. 😢

Everybody who looks at my bike goes "COOL BIKE"...and I've done it all myself with help from my friends here. 😢

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I did the air box mod with the big gun race and the K&N at the same time. I put the dynojet needle in as prescribed on the drz.info site...left the stock jet and pilot in. I set the pilot screw at 3.5 turns out.

Because of this I did not have to take the bowl off the carb. This setup ended up being dead on for the 1000ft of elevation that I ride at. Crisp instant throttle response and an incredible amount of added power. I will note that as of last night I tried a quiet core in my muffler and it killed my performance, and the jetting is off as well. So my prescription is only accurate for the precise systems that I used. You may need to tweek it if you go with a more restrictive system then my Big Gun Race.

The quiet core insert is coming out tonight...and for good.

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I used a sabre saw, covered the intake screen with a plastic bag and rubber band. I threw a rag in the box to grab debris while I cut, then vacumed out the box.

Follow the jetting instructions on DRZ Jetting and you will be THRILLED with the results !! 😢

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