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Yeah you will have to remove the carbs to put the airbox on. If you have soft boots this is the easiest way to do it. kzrider.com/forum/3-carburetor/468219-re...carbs-with-an-airbox
Hope it helps.

how do you get the box back into the frame. i have removed the carbs, and the boots, but it is still really difficult to get the box, boots and carbs back together....i never knew it would be such a PITA to get this thing going. rejetting the carburetors and putting the pod filters on seem to be a pretty good option vs. fighting this old hard to work with, doesnt seem to fit OEM stuff.

harmongreer wrote: how do you get the box back into the frame. i have removed the carbs, and the boots, but it is still really difficult to get the box, boots and carbs back together....i never knew it would be such a PITA to get this thing going. rejetting the carburetors and putting the pod filters on seem to be a pretty good option vs. fighting this old hard to work with, doesnt seem to fit OEM stuff.

New rubber connector boots between the Airbox and Carbs is the best way. Then they flex and fit properly. Rubber turns into some stiff brittle stuff after 25+ years. You wouldn't want to fight them for long, get new ones, then it is pretty easy.

where is the best place to buy the new rubber boots. i cant find anything but overpriced used ones.

It ain't Leggo's thats for sure. Some enjoy working on bikes but if you want simplicity and everything to go by the book it may not be for you. Once straightened out most can enjoy miles of worry free cycling. But some who just fix what is broke usually chase gemlins that eventually leaves a bad taste in their mouths. These are usually old machines that have had some abuse and needs some real work to get them reliable and enjoyable. My uncle and my father got a lot of those bikes that were too much for their new owners. After nearly taking them apart and going through them they would have great bikes but they took the time and did the work others refused to do. The dreams of riding down the road come easy but the reality takes some work. Keep at it and it will pay off.

Once the TK-22's are clean and all of the bowl screws replaced with stainless allens, and the bowl gaskets are good and have a tiny layer of antiseize on them, you can do most jetting and parts replacements without taking the carbs off of the bike. You just have to make some special shorty allen tools (and remember to not overtighten the bolts). On my TK-22 link in my signature, there is a link to the maintenance section which shows photos of the tools I made for rejetting while the carbs are on the bike. It still takes a long time, and you need to get the knack, but there's no back strain at least.

z1enterprises had the boots.

Let's hope removing the carbs to put the airbox on isn't too hard. I should order some boots from Z1.

Just got the new airbox on and the bike runs a hell of a lot better. Found out whoever rebuilt the carbs put #92 jets in when I take #94. Can I just switch them out without tuning the carbs?

Wow, that was a pain in the ass to get the airbox back on. Trying to deal with the cranckcase breather and getting the rubber boots on was an ordeal. Thanks for the link to the post on how to roll back the boots so they fit snugly onto the carbs.

So everything is installed, just need to step up the jets. Any help on this would be appreciated

Glad the tip helped! Welcome back to the world of airboxes! If they are Mikuni CV carbs I found this site very helpful. www.mtsac.edu/~cliff/storage/gs/Mikuni_B...Rebuild_Tutorial.pdf
Good luck!

They put in the 92, probably because that's all that is available in the rebuild kits.

To get 94's, you'll want Keihin small mains. Depending on your exhaust, you may want to go as high as 98. So if you are placing an order, you may want to get 94, 96, and 98. The numbers are the hole diameter in hundredths of mm. The Keihin jets flow slightly differently from the TK mains, but so slightly it's hard to quantify. Either way, since you are rejeting you will want to stick with one type of main to compare.

Here are the details on jets for TK-22's:

home.comcast.net/~loudgpz/GPZweb/TK22mai...22jetsAndDrills.html

Airbox successfully installed! What a PITA. Bike runs better now. No hesitation at low rpms anymore. Although I found whoever rebuilt the carb last put #92 main jets in. Would it be simple enough to go and install #94's in? Will it take significant tuning to get it to work? Thanks