82 GPz750 - Carb/Airbox Installation Help

Bike came with the carb and airbox out. I'm trying to put them in. Is there a trick or order to installing the airbox and carb. Do I need to take the carb holders off the cylinder heads to do it?
Thanks
Nick

It takes some fiddling, but the carb holders go on the head first...then the carbs are installed, then the airbox, then the air cleaner ducts (installing the two inner ducts first). There will be problems installing the ducts unless they are very soft and pliable and you'll have an easier time if you use a tool like a 'radiator hose tool' to aid spreading and forcing the ducts in place. Search this site as there have been recent discussions about this tool and installing air ducts.

Thanks. I was trying to work with the airbox and ducts assembled already.
Nick

I was able to get them on, but what a PIA. I ended up using a heat gun to soften the ducts up and push them through from the inside of the box. I buttoned everything up and I got her running for the first time.
Thanks again
Nick

nicksorg wrote:

I was able to get them on, but what a PIA. I ended up using a heat gun to soften the ducts up and push them through from the inside of the box. I buttoned everything up and I got her running for the first time.
Thanks again
Nick

Exactly! They are a PIA and the heat gun was the trick that others have used.

I read about this in several fourums and tryed it with good results so far soaked the boots in xylene for 24 hrs her are some picks they swelled up but others have said they will return to original size ill keep ya posted they are really soft and plyable now compared to hard as rock.

some more

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Another version of softening liquids:

Successfully Resurrecting Old Rubber Parts
(Found on the internet)

This subject has been broached before but I am happy to report success in revitalizing old rubber.

I have been using a mixture of 30% wintergreen oil (methyl salicylate) and 70% xylene to restore old rubber parts and it works beautifully. This is the same ingredients and proportions for the commercial product Rubber Renue according to the MSDS sheets.

Wintergreen oil is analgesic and liniment for aching muscles and found in most drugstores, pharmacies, health food stores and co-ops.

I gently heated rock hard honda CB carb boots with a heat gun for 30 seconds and dropped them into mason jars with my solution for 12 hours at room temperature. They come soft, pliable and looking good. They have been out of solution for 48 hours now and are still soft and pliable. I soaked smaller rubber parts such as side panel grommets and there extremely soft and may need to soak for less time.

Also says forget the wintergreen just use straight xylene thats what I did.So 12 bucks for 1 ltr of xylene usually found a a paint supply store.D

Taking the bolts out of the battery box gives you a little extra room too. Put throttle cable on before carbs are in manifolds or youll wish you had.