TOPIC:

Everyone hates removing carbs with an airbox. Maybe this will help. It is on my 82 KZ650 CSR but I also do it on my 77 KZ650 B1 and was taught on a 76 KZ900 LTD to do it this way.

#1 is you must have new or SOFT boots.
To remove the carb bank push the boots into the airbox. Once you have done this the carbs will come out easy with plenty of room.


Now for the part everyone hates
Installing the carbs
#1 Remove the boots from the airbox

#2 Now fold over the outer flange on itself. It's pretty easy.

#3 Now put the boot back into the airbox as it should be but with the flange folded over. Pay attention to position the boot correctly as the outer ones are curved. Usually a pin and notch shows the position.

#4 Now you have an extra inch to slide the carb bank back into place. DO IT!
#5 With the carbs back in place and secured, unfold the folded flange onto the carb throats (easy), install the spring keepers and Bob's yer Uncle.

I hope this helps make a tough job easy and convinces some to stick with the airbox. Pods look nice and all but they do come with headaches, a learning curve and not everyone has the expertise or wants the expertise to make pods run good. Above all make sure you do your homework if you are thinking about removing your airbox. It is not easy to remove and harder to re-install if you get disappointed by the pods. Above all else NEVER destroy your airbox to remove it. You will find a hard time replacing it and at the least you might get some money for it from someone who didn't listen up. This tip will at least make working with the airbox easier. Good Luck

Awsome tip, so what you do to soften up the old, dry, hard boots? Delcolax? LOL guess I need to order some new ones from Z1 when the banking account permits.

A heat gun works well to soften hard boots. You could trey a hair dryer.
New and soft is best.

elfmagic17 wrote: Awsome tip, so what you do to soften up the old, dry, hard boots? Delcolax? LOL guess I need to order some new ones from Z1 when the banking account permits.

Well since you asked: I have no tips on softening hard boots. In my opinion once hard always hard. At least too hard to use that tip. But if you do spend the wad, break the bank, hock the ole lady and get new boots I seem to have pretty good luck with waxing/oiling them up every week or so. Seems to keep them soft a lot longer. Not forever but much longer than if you don't. Takes a minute. I kinda like the gel wax. Does Ducolax come in a gel cap?

I would roll the Spring clamp either onto the Boot, or the Airhorn/ rear of the Carb. Those inside two can be a bit tough to re-hook.
Soft boots are the Key, with those nice and pliable, they go in and out pretty quick. A nice 90 degree hook tool makes restarting them onto the carb easy, then rolling the spring into place.
Probably no where near the ease of removing the Pod's and having Lots of room. But if you get those carbs real clean, correctly jetted, have a good fuel tank and filter. How often do you need to remove them?

Having a radiator hose tool helps a ton installing boots/carbs on any bike. I call it "The Ultimate Tool" because I use it for so much crap. Snap-on has short and long reaches. Be careful not to peirce the boot though.

Motor Head wrote: I would roll the Spring clamp either onto the Boot, or the Airhorn/ rear of the Carb. Those inside two can be a bit tough to re-hook.
Soft boots are the Key, with those nice and pliable, they go in and out pretty quick. A nice 90 degree hook tool makes restarting them onto the carb easy, then rolling the spring into place.
Probably no where near the ease of removing the Pod's and having Lots of room. But if you get those carbs real clean, correctly jetted, have a good fuel tank and filter. How often do you need to remove them?

Excellent advice; and to answer your question - in my case only twice in 34 years.

My choice of weapons are Hemostats(Forceps) One straight and one curved. Indispensable tools!

Is there any other way to soften the hard boots? I am having trouble finding any new ones in stock on any website. I've heard you can boil them to soften them, is this true or a myth?

I have heard soaking them in Xylene for 15 minutes will soften them up, but do it outside with good ventilation. I've never tried it myself though.

There is a thread or two around here in which some folks claim that boiling them in wintergreen will soften them up for a while. I have not read about a permanent solution other than new boots.

Here is a thread that mentions wintergreen, wintergreen plus alcohol, and wintergreen plus xylene.

www.kzrider.com/forum/3-carburetor/60305...allation-help#740917