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Q1 same air box different assembly-220

PostPosted: 06:26 pm Feb 12 2018
by freeindeed
Hi. I just got a 2001 KDX220 in Dec. 2017, so I am going through it.

The stock 2001 air box has the rubber air boot clamped with the square boot clamp completely to the OUTSIDE of the plastic air box with the flat side of the square CLAMP toward the carburetor. The square CLAMP bulges out between fasteners. This is apparently how it came assembled from the factory.

Since I was not sure if it was assembled correctly, (even after looking at the service manual), I bought a stock 2006 KDX200 air box assembly near new.
Sure enough, the newer air box has identical parts but it is assembled differently. One end of the air boot goes INSIDE the plastic air box unlike the 2001 which was OUTSIDE the air box. The air filter base was pressed against the air boot on the inside of the air box unlike the 2001 which which the air filter base was pressed against the air box itself. And The square boot CLAMP was clamped directly to the air box with the flat side toward the air box (which is reversed from the 2001).

Which assembly is correct?
Is grease or adhesive recommended between the air boot and the air box?

Re: Q1 same air box different assembly-220

PostPosted: 03:52 pm Feb 15 2018
by freeindeed
So basically I was asking if the boot from the carburetor goes inside or outside the air box.
(But I understand if nobody wants to take theirs apart to find out.)
I ended up assembling the boot INSIDE the air box since the 2006 air box (with less miles and less chance someone messed with it) had that arrangement.
And I used Maxima high temp. grease on all the sealing surfaces.
If you think that is wrong let me know.

Re: Q1 same air box different assembly-220

PostPosted: 07:19 pm Feb 15 2018
by bufftester
On my 2001 220 the rubber boot is bolted to the outside of the airbox. Same on my 2003 KX. I don't think it makes a lot of difference as long as it is sealed.

Re: Q1 same air box different assembly-220

PostPosted: 12:47 pm Feb 17 2018
by freeindeed
Thanks for verifying your assembly.
Yes my 2001 220 was bolted to the outside also. But I noticed the clamp bulged outward between screws from the air boot lip.
So I went with the 2006 assembly because the air boot lip looks like it was made to fit inside the air filter base on the inside of air box. And all layers sit flat now with no bulging.