Ordered a K&N filter and it doesn't fit..WTF?

Local shop verified that the part # was correct for my '06 but the flange height of the new element would not allow for the top of my airbox to seat properly. What's up with that?

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Remove the O-ring in the groove of the airbox lid. If that doesn't do it, remove the one in the lower half of the airbox too.

common thing with all K&N filters and VFR800s.

Yeah, you have to remove both those gaskets from the air box. Or you can be an idiot like me and ride around with it the way you have it pictured for a year before you figure it out..........

Mike

The thickness of each gasket removed from the upper and lower halves of the air box is still not enough to allow for everything to close up properly with the K&N filter. Have you guys had to trim the K&N filter also?

Ok, now THAT'S a new one!!!

remove both the o-rings from the box...

[image: View Post]AnikMankar, on 26 March 2012 - 07:18 AM, said:

remove both the o-rings from the box...

He just did.......

Cool, thanks, I'm about to order a K&N and I'm sure I would have had the same question

How large is the gap between the lid and the lower half of the airbox before you tighten the screws? It should be a few mm.

I had the same problem when I put mine in years ago.  Some careful trimming with a box cutter made every thing work just fine.  No problems since.

If both the o rings are out and the filter is gasketing into the crevices the o rings sat in, you should be fine. The rubber portion of the filter may still show, but as long as it is sealing to both halves of the airbox, you're fine.

Mike

I removed the o rings and just had to be careful to make sure the K&N was down in the groove all the way. Fits great.

How close is it to closing? To be technical, if the rubber is squished enough, it will create a seal around the groove. The air box doesn't NEED to be sitting flush so long as nothing can actually get through the crack.

When I installed a K&N air filter on the VFR I didn't have fitment issue after removing both O-ring. It is a tight fit, but that's the purpose. You don't want air to enter the air box from anywhere outside the filter element.

After removing both airbox O Rings (I'm a dumb ass for not doing this originally...The instructions that come with the filter actually mention this!) it was a very tight fit. I torqued down on the screws and clamped down on the K&N's gasket real tight. There's stil a small space between both airbox halves furthest from the screws but all is good now.

Gunzer

[image: View Post]Gunzer06, on 28 March 2012 - 04:00 AM, said:

After removing both airbox O Rings (I'm a dumb ass for not doing this originally...The instructions that come with the filter actually mention this!) it was a very tight fit. I torqued down on the screws and clamped down on the K&N's gasket real tight. There's stil a small space between both airbox halves furthest from the screws but all is good now.

Gunzer

The seal of the filter is good - you should have no issues...a little gap is allowed. Dont over tight the screws the tabs on the top cover will break-off. Learnt the hard way !!

Sounds like good advice. I can certainly back off on those screws a bit.

Thanks again,

Gunzer