Air box doesn't fit any more

[DnKSeadoo]

Hi all, I replaced the engine in our 96' Sportster over the winter. Since then we have moved from the Midwest to arizona. I ran the engine before we left but now I am finishing it up and the cover for the air box doesn't fit anymore. Seems to be too big for the base. It wasn't damaged in the move at all. It has been apart for about 5 months.
Has anybody seen this before?

 

[Dr Honda]

Flip it around. (lol) It's not quite symmetrical.

 

[DnKSeadoo]

I have tried it both ways; on and off the boat. Sorry didn't mention that.

 

[Dr Honda]

is it just the top cover? If it is... the rubber ring may be tight. Make sure it's on flat... and put a little grease around it, to help it all slide together.

 

[DnKSeadoo]

It seems like the top cover has expanded. It sounds crazy. I have all the clips off and the ring that goes around. I can get it around three sides and the last one seems really far off. I will try to post a picture

 

[1MACGYVER]

Not sure if its the same but i had an argument with a similar seal on an XP coil box, it turned out the seal had jammed down into the slot instead of sitting higher up on the lip (I apologise if that makes no sense), it seemed so simple once i realised but it looked right before .

Try removing the rubber seal and fitting it then if that works try with the seal in different positions

 

[Dr Honda]

Ummm....


Yep... looks like something shrunk. Well... the good news is... that box is a dime-a-dozen. So... I'm sure you can get one cheap. I probably have a couple at my shop. If I do... you can have it for the cost of the shipping.

 

[DnKSeadoo]

That would be great. Let me know if you do and how much to ship. My zip is 85379 Surprise AZ