Air Filter Mod

This mod is shown on my '84 ZG, but the set-up should be similar on the carb models (I think the difference being the tools are kept where the D.F.I. control box is). It does away with the restrictive snorkel on the upper air box & offers unhindered airflow into the filter which liberates a few extra horses, especially at the top end (as well as some lovely induction noise). The snorkel was used to counteract induction noise by Kawasaki, at the expense of some power. This mod also retains the surge tank (lower airbox) that Kawasaki designed in, which you'd lose if you fitted individual K&N's to the bell mouths. If you decide to do this mod a less restrictive exhaust is recommended & re-jetting/mixture adjustment is a must to avoid the engine running lean. On the D.F.I. models you can richen the mixture by adjusting the throttle position sensor with the aid of a colour tune plug.

Pic 1 shows the plinth left when you remove the upper air box. The studs are 1xM8 & 2xM6. The two M6 studs screw into the threaded inserts that originally secured the upper air box & the M8 stud is fixed to the fabricated bracket shown.

Pic 2 shows the new position of the air temp. sensor on the D.F.I. models, originally attached to the upper air box, now attached through the back panel of the standard shape K&N filter element. Hopefully you'll be able to attach it straight, unlike me...lol.

Pic 3 shows the filter element in place. A hole is drilled in the upper panel of the filter & the M8 stud passes up inside & out through the top. The fibre washer shown is to seal around the stud when the D.F.I control box carrier goes on top, which I later changed to a rubber washer that compresses & thus offers a better seal.

Pic 4 shows the D.F.I. control box carrier in place. As the nuts are tightened the rubber gasket on the bottom face of the filter is compressed against the plinth, achieving an air-tight seal.

Pic 5 shows the D.F.I control box back in it's carrier. The beauty of this mod is that it can be reverted back to the standard set up if required. I should also point out that this mod works best with a K&N element, not only because of the increased airflow that these units offer but because you won't want to be having to drill a hole in the standard paper one every time you replace it.