The rubber airbox boot on my 125 is about as plyable as steel, which makes putting the carb in a real pain. I've got a spare 250 boot that is much softer. The parts are almost identical apart from the 250 looks to have about 5 - 10% more volume in the section behind the frame. Before I go to the lengths of bolting and silicon'ing it on does anyone know if it would affect the power characteristics? Thanks.
If the volume is different the power characteristics will change. But because the volume is upstream of the reeds and crankcase it will be minimal. Reed stuffers are used to remove some of that volume on many bikes. Removal of the reed stuffers is really hard to feel.