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carb mounting help desperately needed

Discussion in 'XJ Technical Chat' started by Ltdave, Aug 29, 2007.

  1. Ltdave

    Ltdave Member

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    okay, after much screwing around my carbs are ready to be mounted...

    ive got them in the carb holder boots (to the head) because it looked like the easiest route to take as a first step...

    how on God's green earth do i get the airbox boots in place?

    ive turned and twisted, stood on the other side of the bike, laid down and done everything short of standing on my head trying to figure out how these things all fit into place...

    can someone bail me out here?

    thanks

    d
     
  2. Lohnair

    Lohnair Member

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    Brute force worked for me. Feed the joints through the inside of the airbox, and then work them from the outside, pulling, to get the joints to pop into place through the openings. Once all four are in place, slide the airbox foward and secure. You may have to wiggle the joints some to get them seated correctly. Also, make sure that when you pull them through that the tabs on the joints fit between the little pegs on the outside of the openings. Should be vertical.

    I've heard that if you soak the joints in some hot water for a bit, they become more pliable and easier to work, but I haven't tried it.
     
  3. vinco

    vinco Member

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    1. Take the airbox boots out of the airbox from the backside, being sure to keep them in proper order for reassembly into the same holes.

    2. Each one in turn, take the part of the boot that slips over the carb inlet, and with your fingers, fold it out and back on itself, like the cuff in your pants. There is kind of a point where it naturally folds back.

    3. Slide the folded boot between the carb and airbox into position, allowing the velocity stack part of the boot to go into its correct hole. Then work it in to seat the groove onto the airbox in the right spot.

    4. Give the carb neck part of the boot a flick and watch it neatly unfold itself perfectly back into place over the carb inlet.

    5. Split the clamp to put it back over the boot neck, then tighten it as normal.

    This takes about 10-12 minutes, whereas the old brute-force method took me over an hour.
     
  4. RickCoMatic

    RickCoMatic Well-Known Member

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    Line them up and look that all four.
    The two that are "Straight" (or the straightest) are 2 & 3.
    The other two are outboard boots.

    Here's a GREAT trick I learned just last week!

    Take the four Boots and wrap them in a wet dish towel.
    Microwave the (Rubber Only) Boots for 45-Seconds.

    Bring the very warm and pliable boots down for installation.

    Do #-3
    Push it into the Airbox and work with it while its still warm.
    Do #-2
    Same
    Do #-4
    Do #-1 Last.

    If you have an assistant with the Clamps and screws ... put them on and line them up.
    Tighten down 2 & 3 after you get them on so you don't have to work around 1 & 4 to get to them later.
     
  5. Ltdave

    Ltdave Member

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    oops... about 3 weeks too late for THIS to happen...

    okay, i used Vinco's method and had them on and clamped in 18 minutes...

    this is a great tip...

    thanks

    d
     
  6. thefox

    thefox Member

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    OK, I am going to save this thread! If it works half as well as you guys make it sound then this will be the best thing I have read all year (don't tell my engineering professors I said that though!). Putting these carbs. on has been the worst job i have had to do on this bike.
     
  7. Stooge

    Stooge Member

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    FWIW, just did this last night. My carb inlets are numbered under the brackets.

    I used the method of pushing them into the airbox and pulling them out once the carbs where in. however, I didn't index mark them to make sure the have the correct rotation. My bad. Worked ok, but I'm trying the fold back method.
     
  8. Lohnair

    Lohnair Member

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    I like those ideas. No more brute force for me.
     
  9. Hvnbnd

    Hvnbnd Active Member

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    I usually do it the same as Stooge, I push them into the air box then I have this tool thats bent at the end that helps slide them out of the bos and onto the carb.

    Not too bad that way.
     
  10. Robert

    Robert Active Member

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    I just wrassled with my boots for an hour last week, royal PITA that job is!
     
  11. RickCoMatic

    RickCoMatic Well-Known Member

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    I made-up the same tool ... I call it my "Shoe horn"

    Works great for getting those stubborn boots up onto the outsides of those big Intake ends.
     
  12. Robert

    Robert Active Member

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    I would love to see a picture of that "shoe horn" Rick.
     
  13. RickCoMatic

    RickCoMatic Well-Known Member

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    Shoe horn
     
  14. Robert

    Robert Active Member

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    I've been using a mechinists scribe and a very careful hand!
     
  15. RickCoMatic

    RickCoMatic Well-Known Member

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    I put a flat right-angle on the end and sanded it down to have dull edges, so it won't cit or penetrate the runner.

    The "S" runs parallel to the bent end so you know what angle it's at just by handling the tool. The outside is smoothed to let it push without binding.

    Saves a whole lot of time.
    But, I also smear some waterproof grease in the Airbox Boot locating channel to make it rotate within its circumference without the big fight.
     
  16. tebo

    tebo Member

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    I removed the 1 bolt and 2 screws from the air box. it lets it move back a half inch or so and the boots slid in very easily.
     
  17. thefox

    thefox Member

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    OK I was trying this tonight and couldn't get it to work. When I folded the boots back on themselves I still don't have enough room to cram the boot between the carb and air box. They also don't stay folded very well.

    Any help? I have to get these on because I won't be back to work on the bike until December, working in 20 degree weather is not much fun so I really want to get them on now.
     
  18. Robert

    Robert Active Member

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    Drop them in hot water, they will get nice and soft for a very short while. Long enough for you to weasle them into place.
     
  19. thefox

    thefox Member

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    I wrapped them in a wet towel and microwaved them, they are flexible but there still isn't enough room to get them in there.

    This has to be the worst job on these things.
     
  20. RickCoMatic

    RickCoMatic Well-Known Member

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    You have to be a little rough with those airbox boots.
    Get it warmed up and stuff them back into the airbox.
    Once you get them back in the airbox you have to fight with them to get them back on the carbs.

    I have a home made tool that I use. Its like a shoe horn. No sharp edges to poke or pip the rubber.

    Do the inside two and then the outside two. It helps if you open the airbox and take out the filter. you can reach in there and help push them around.
     

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