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So, this crazy idea came into my head a while back of trying to squeeze 40hp out of the Ninja using only stock parts and modifying them... We'll see how much I break those rules.... Either way, I got the extra exhaust can set up with the machine shop guy and I started fiddling with the bike.... I got the needles shimmed this time without pinching the diaphragms, and the bike seems to run a little rich with 2 washers... So I got to thinking, and I might be paying (again), for doing that... Why take away gas, when I can add air....
So here's my airbox mod:
First you take off:
1.) Front Fairings
2.) Seat
3.) Tank
4.) Rear fairing/passenger seat/rear cowl
5.) Rear wheel
6.) Rear fender
7.) Exhaust mount/support/passenger peg, and passenger peg on left side
8.) Battery and box
9.) Then you're in a place to get to the airbox.... Just undo the round clamp rings and slide off carbs... I found this out the hard way...
Then, after about 3 hours of dissasembly (I might be slow, but I'm thorough) you can get to this:
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Notice the two holes on the right, this where the rubber boots go to connect the airbox with the carbs...
Start cutting:
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and cutting:
![]()
and cutting:
![]()
and cutting, and filing down the "ribs" inside the airbox to make way for my cover:
![]()
at this point, I also cut up the rubber boots going between the airbox and carbs:
![]()
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And then I took the metal screen that was behind the foam filter (picture 1), and started cutting it up. I needed something that was going to keep large debri out of the box, being that it's right above the wheel, and probably experienced some kick up:
![]()
Cut and bent out of focus:
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Mounted to the airbox with M2-12mm screws and nuts - they fit perfectly between the holes of the screen:
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So, right now the bike looks like this:
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Then I put it partially back together and tested, and got some alarming results. I thought it was because it was cold, and it still might be, I haven't tested thoroughly enough yet - that will be tomorrow. Maybe you fellas can give it a hear and tell me what you think. The hesitation you hear is right at 8,000rpm... Am I WAY lean now with so much more air capable or entering the airbox?
Kawasaki 250R Aibox modification - www.newninja.com
So here's my airbox mod:
First you take off:
1.) Front Fairings
2.) Seat
3.) Tank
4.) Rear fairing/passenger seat/rear cowl
5.) Rear wheel
6.) Rear fender
7.) Exhaust mount/support/passenger peg, and passenger peg on left side
8.) Battery and box
9.) Then you're in a place to get to the airbox.... Just undo the round clamp rings and slide off carbs... I found this out the hard way...
Then, after about 3 hours of dissasembly (I might be slow, but I'm thorough) you can get to this:
Notice the two holes on the right, this where the rubber boots go to connect the airbox with the carbs...
Start cutting:
and cutting:
and cutting:
and cutting, and filing down the "ribs" inside the airbox to make way for my cover:
at this point, I also cut up the rubber boots going between the airbox and carbs:
And then I took the metal screen that was behind the foam filter (picture 1), and started cutting it up. I needed something that was going to keep large debri out of the box, being that it's right above the wheel, and probably experienced some kick up:
Cut and bent out of focus:
Mounted to the airbox with M2-12mm screws and nuts - they fit perfectly between the holes of the screen:
So, right now the bike looks like this:
Then I put it partially back together and tested, and got some alarming results. I thought it was because it was cold, and it still might be, I haven't tested thoroughly enough yet - that will be tomorrow. Maybe you fellas can give it a hear and tell me what you think. The hesitation you hear is right at 8,000rpm... Am I WAY lean now with so much more air capable or entering the airbox?
Kawasaki 250R Aibox modification - www.newninja.com
