How do I get the carbs and airbox together?

Well its been a few years and a few bikes since I have been here, but I am back with a new project. I just got a 6/82 kz750H. It came pretty much complete but not running. After rebuilding the carbs I went a bought an airbox for it. Now my question.. how the heck do you get the carbs in the intakes and the airbox boots on the carbs at one time. I am not some rookie at mcycle mechanics but after an hour+ I figured that someone may know a trick or two. Anyone with a trick or idea to offer would be greatly appreciated. The bike runs now but it has been my experience that it will do so better with the airbox attached.

the air boots will slide back into the iar box, you will mount the carbs into the intakes, then one by one working from the middle out push the boots forward and then using a dull flathead driver or rounded off ice pick like tool (as a shoe horn for say) pry the boots back over the carburetors.

P-I-T-A for sure, but you will manage.

If the boots are in good shape and not too hard fold them over on themselves. This will give you an additional inch+. Then install the rack to the head. Unfold the boots onto the carbs. It is the easiest way I know of if you have soft boots. I will always buy new boots if they are not soft enough. I have heard if you heat the boots they get softer but my experience is different.

I sometimes spray the boots with silicone, makes them much easier to work with. Just make sure that it doesn't get into the carbs/engine.

I actually got the boots onto the carbs by doing just that, pushing the boot into the airbox. My problem is I cant seem to move the boot enough to get them to actually seat in the box again.

Did you see this old thread? tinyurl.com/2edfsb I do the same thing that Ambergrismooon does. Makes it easy.

I realize money is tight for most of us but after fighting my 28 year old hard as a rock shrunken boots (heating (melted!)lubing, etc) I decided F**k it and spent the money on nice new soft ones. Now I just insert inside air box and work onto carbs. Pretty easy now, especially on a warm day! Trust me, worth every penny!!

Definitely buy new ones if they still make them!!! see thread "Need Expertise on Rubber Softeners". Until I bought new inlet ducts, I was seriously considering pods (which would require bigger jets, I believe).

Well I thank you all for the good advice. Now can anyone lead me in the direction of new intake boots and does anyone have a ball park figure on cost?

Z1E comes highly recommended!


Z1E

New boots are the best, but I have had success by using a hair dryer and heating each boot, one at a time for several minutes, then inserting it through the air box and toward the carb. Then use a large flat screwdriver to carefully push on the edge of the boot to slip it onto the carb, with the help of your other hand on the opposite side. Sometimes you have to use a smaller screwdriver to insert inside the boot to help it get over the outer edge of the carb. Keep applying heat as you work. This is not an easy job, hence the new boots are sweet.

Easy on the silicone spray. If you get it on paint it will never come off and will screw up any re-paint you do. No first-hand experience with this but heard it from a painter-friend. The stuff is banned from his garage.