@#$%! Carb boots

Maybe this is me, I pulled the carb rack back to remove & inspect the intake boots (carb to Cyl) & replace bolts with new stainless bolts anti seize etc. I had to just stop last night before I really got medieval on the Max. everything came apart just fine, now trying to get the airbox side boots back up to fit the carbs seems nearly impossible. they are still pliable but is if they freaking shrunk. has anyone seen this? if so what was your resolution? buy new?? kind of irritating that it came apart fine though, thanks all, be safe

 

I clamped one carb (#1 or #4) into it's boot, then pushed the other side until they all popped back in. They are difficult to get back in, but i dont think new ones are in order unless yours are cracked or worn significantly.

 

They're a pain in the butt and take a lot of wiggling and flexing to get on again and seated into the airbox properly - but it can be done.
I just start with mounting the carbs to the boots on the cylinder head, then wiggle the airbox ones in starting with the inside ones.
Time and frustration are all it takes....

 

You can also warm them with a spotlight to make them a little more flexible. (Don't burn yourself, or bike parts.)

Make sure the airbox is loose, and also use a dental pick or pointy mechanical probe to help the lips of the boots into position.

Z

 

Judging from what you guy's have said, it sounds like your saying to clamp them on the carbs first, then push them back torwards the airbox until the grooves in the boots pop back into place? If so I will try that, I pulled the boots back into place in the airbox first, & now am trying to get them up onto the carbs. Thanks for the quick response.

 

I believe gremlin484 was referring to the manifold side of things.

Once all four carbs are popped back into the manifold intakes you have work the air filter boots around each carb. Then clamp everything down and attach the cables.

Make sure the throttle cable has a little play, even when the handle bars are cranked both ways.

Z

 

Yeah, my first post was about the carb to cylinder, sorry, I misread.

I had to replace a few of the clamps on the airbox to carb boots, but once you clamp them to the carbs first, they are a lot easier to manage. I ran into the problem of my airbox being a little warped, so I had to kind of stretch the boots into the airbox. I also found that if you have one that goes in easy, and one that looks like it's not long enough, swap them around. I wondered if maybe the outer boots stretch a little over time, so if you try and put a boot that was on #2 or #3 on to the outer carbs, you'll be short.

 

The best thing to do takes a bit of time. Pull all those rubber boots right out of the airbox and hand-sand the airbox holes with some 320 to give you some play.

Then, resand the edges with 400 and 600 to make them as smooth as a baby's ass. Shop-Vac. Clean; etc.

Re-install the boots. Push 'em all right into the airbox after you smear the "Mounting channels" with some waterproof synthetic grease. Makes 'em easy to rotate.

Reach in. Push #2 out and channel it. Rotate it from the inside while you use a little homemade "shoe horn" to get the lip over the carb intake.
There's an indicator and pips on the airbox for line-up ... look for them.

Do 2, then 3 ... then, 1 and 4.
Nice work!

 

I've been successful at carb install using silicone grease or WD 40 in a pinch. They always pop right in when properly lubed.

 

I just did this last week, just takes a long time and patience everthing will eventually fall into place. Take your time. I found that warm rubber is much more pliable and lubricant goes a long way.

 

I remember when i first yanked off the carbs off my maxim. It took me about 2 hours to remove and reinstall. I removed the rubber boots first and then removed the carbs. I had a hard time re installing the boots, but i found out that even after 25 years, those rubber boots were still very flexible abd durable. After i wrestled the first one in (i literally folded the dam thing in half), i had confidence in the other boots and they all made it back in. I highly suggest following Rick's order of installation to save time and grief.

 

I always stuff mine into the air filter box to give me room.
Pull them out from the inside 2 to the outside 2, one at a time.

I also have a tool that works great like a shoe horn like Rick was saying.