Originally posted by Glitch_Oz in this post:
I just thought i'd make a new post since his was in the Austraila section and i had some info to make it easier for those of us in the States to do it.
After initially seeing this post i finally got around to making my own new filter today. Being in the states that brand he used was not available here(or at least in my area). So i sorted through many air filters and found a near perfect fit at Orileys Auto Parts. It is there house brand Micro Guard(made by Purolator) part # GA33590. Cost was $5.29
With this one there is no cutting of the filter involved. Its fits right over the square cut out in the air filter. So you have a rubber seal all the way around.
It is a bit taller than the stock one, but fits in the lid just fine.
I used the same procedures as Glitch Oz did and it worked out great.
Here is how its done.
Pull your stock filter out of your bike and cut the stock air filter material out of the plastic.
Next use a grinder, dremal, hacksaw.. sander.. whatever to cut off the plastic sides that held the air filter material in off and make them smooth with the plastic base plate.
The GA33590 air filter is nearly a perfect fit for the square cutout in the base plate. This filter is taller than the stock filter so to give a nice flat sealing surface and to gain the needed clearance you will need to grind down the rubber gasket edge on the new filter so it is nice and flat. I used a sand flap wheel on a 4" grinder.
Here is the filter gasket when new.
Here is the rubber gasket after grind it down.
Next run a bead of silicone(or any rubber compatable sealant) around the base plate opening.
Carfully line up and place the new filter on the base plate. Make sure it is pressed down and sealed with the silicone all the way around.
You can lay something heavy on top of the filter to help keep it pressed down while the silicone dries.
After it dries you are ready to put it back in your bike. The new filter is a snug fit in there since its taller, but fits just fine.
Then next time all you have to do is cut the silicone and add another new filter.
Thanks again to Glitch_Oz for the original idea!