Sport Air Filter box – Yamaha T-Max 500 2001-2003

High-Flow Sport Air Filter for Yamaha T-Max 500 2001 1st Gen (Box + Filter Setup)
 

⚡ Updated Model – V2 with larger hexagonal grid
The original design used 12mm hexagons. After calculations and community feedback, the new V2 uses 35mm hexagons with 3mm walls, increasing the effective open area significantly. If you downloaded the old version, grab the new one – it flows better.

A fully custom 3D printed high-flow air filter housing designed to replace the restrictive OEM paper filter unit on the first generation T-Max 500 with carburetors.
 

Why this should outperform stock:

The OEM filter uses corrugated paper media which, while having decent surface area, is significantly more restrictive than open-cell foam. The Polini Original Air Filter foam used here is a high-flow dual-layer performance filter – the same type used in racing applications. Open-cell foam of this grade typically flows 3-5x more air per cm² than paper. Combined with the large 35mm hexagonal open grid (85%+ open area, ~117 cm² effective flow area), this setup should deliver noticeably better airflow especially at high RPM where the engine is starved for air.
 

Ideal for modified T-Max 500 with:

• Sport exhaust
• Polini Hi-Speed variator with light rollers
• Naked conversion

Important – modification required:
The intake hose that connects to the filter box is designed to sit deeper (for the taller OEM arch filter). Since this housing is flat, you will need to trim the hose slightly so it sits flush and seals properly.

Filter setup:

• Polini Original Air Filter sheet (A3 format, dual-layer high-flow foam)
• Outer layer: black 30 PPI (coarse dust pre-filter)
• Inner layer: blue 60 PPI (fine filtration)
• Oil: Mannol Air Filter Oil spray

Print material: ASA or PETG
Dimensions: 102.2 × 107.2 mm

If anyone does a real-world or dyno test I'd love to hear the results! 🏍️