Air Ducts

Is there a trick to connecting the air ducts between the carb and the airbox?? Its 79 KZ 650, and I've been trying to get them squeezed through the airbox hole for about an hour now, and am ready to pull my hair out.
Thanks,
Ed

I install mine through the air box also but trying to squeeze old hard boots is almost impossible. There have been many chats here about boiling them in water, microwaveing (tried it, melted!) laying in sun, etc. Now I'm gonna tell you what you know, but don't want to hear.... by some nice new SOFT carb boots from Z1!

Post edited by: Bluemeanie, at: 2008/02/07 16:51

When you are done pulling out your hair, just buy pods and re-jet. I have hated air boxes my entire riding life. The rubber gets hard and then routine maintenance becomes a nightmare.

Or it could be that I am a Lazy Sack...

Seriously, I think you can soften them up. I have soaked hard rubber parts in Armor-all with some success. The silicone in Armor-all also makes things slippery and they tend to slide into place easier.

I second the brand new boots. They will work, well, like new!

Good luck!

Post edited by: andoman, at: 2008/02/07 16:52

What I used to do (before fitting a Henry Abe air filter) was to install the air ducts through the airbox. Remove the air filter, stick the duct down the airbox and through the hole - get the groove on the duct started and use a small screwdriver to pry around the groove on the outside of the airbox while having one hand down the box to hold the duct from behind.

If the ducts are hardened a minute or two in hot/boiling water will make them soften up, install them while they´re still warm.


Wow, you guys are fast... :S

Post edited by: OnkelB, at: 2008/02/07 16:58

That was fast... I think I want to rejett and get pods on it, but for now I just want to get the old ones back on so I can get around. They won't melt in boiling water will they...? Trying to think what my grandma would say if she came home while cooking carb parts in her pot. Haha. I think I'll try boiling then use some WD 40.
Thanks,
Ed

No, they won´t melt, at least not in a minute or two, but they´ll only stay soft as long as they´re warm, once they cool off they´ll harden again so you might want to do one or two at a time.

Thanks a ton for the help. I boiled some water and held the hard part in the water for about 45 seconds, ran outside and they went in easy as... well, really easy. After a couple minutes they are already hard and in perfect. If it wasn't so dreary out, I'd be on the bike and going for my first ride in about two weeks. I'd definitely recommend this method. Thanks again,
Ed

Now that wasn't too bad, huh?

No problem, only glad to help.

Rather than a screwdriver or other sharp metal object, I use an old tooth brush that has a wide blunt plastic handle to help work the boot into place. So far, so good.

I'm with Bluemeanie on this one.

In the end I just bought a set from Z1 because it was taking the all fun out of wrenching.

Best of success!

If you don't get them on before they cool, you can warm them back up with a hair dryer or a heat gun on low setting.