Carb to Manifold Boots installation.

How difficult is it to change the Carb-To-Manifold boots on a KZ650 with the carbs still on the bike?

Do the carbs need to come off completely?

I found a vacuum leak in the cylinder #2 connection boot from the carb to the manifold, which has been the source of plug fouling across all the cylinders, and poor fuel economy.

I'd pull the carbs so you can get an impact driver aimed at the screws. They can be a real bear to remove. A #3 phillips will get er done. You just need to find/make room to swing the hammer.

vacuum leak from the CARB to the MANIFOLD suggest the clips if fitted at all, are not tight. Is the Manifold split? where exactly is the leak? Does it actually need new manifolds? A leak in one carb rubber will not affect other cylinders. If anything, that one cylinder will run weak not rich. Or.... you could just throw some more money at it in the hope it will work rather than diagnosing and resolving the actual issue !:whistle:

Pull the airbox too. You might be able to use a universal attachment on the driver head and a long extension to get in there. It would help to have an extra set of hands to hold the bit snugly on the screw while you wack it.
Steve

SWest wrote: Pull the airbox too. You might be able to use a universal attachment on the driver head and a long extension to get in there. It would help to have an extra set of hands to hold the bit snugly on the screw while you wack it.
Steve

Appreciate it

Warren3200gt wrote: vacuum leak from the CARB to the MANIFOLD suggest the clips if fitted at all, are not tight. Is the Manifold split? where exactly is the leak? Does it actually need new manifolds? A leak in one carb rubber will not affect other cylinders. If anything, that one cylinder will run weak not rich. Or.... you could just throw some more money at it in the hope it will work rather than diagnosing and resolving the actual issue !:whistle:

Thanks for all the advice.

Warren3200gt wrote: vacuum leak from the CARB to the MANIFOLD suggest the clips if fitted at all, are not tight. Is the Manifold split? where exactly is the leak? Does it actually need new manifolds? A leak in one carb rubber will not affect other cylinders. If anything, that one cylinder will run weak not rich. Or.... you could just throw some more money at it in the hope it will work rather than diagnosing and resolving the actual issue !:whistle:

My intrepid son would not give up.

He pulled the coils off and tested them. This entire time the problem was the coils. After a 25 mile ride yesterday on new plugs. all four cylinder plugs were fouled rich, not oil fouled, carbon fouled. Weak Spark. Ive ordered Dyna coils. Problem solved.

Did you check voltage at the coils? It's quite common for resistance to build up in the harness which drops voltage reaching the coils, which can cause weak spark. The coils are actually quite robust. And be careful when ordering coils to get the right type. There are various types for good reason.

The green coils will work.
Steve

Nessism wrote: Did you check voltage at the coils? It's quite common for resistance to build up in the harness which drops voltage reaching the coils, which can cause weak spark. The coils are actually quite robust. And be careful when ordering coils to get the right type. There are various types for good reason.

Yes my son checked the voltage to the coils, and it was fine.

Its the coils themselves that are bad, and if they are what was originally on the bike, they are way way overdue for change.
Though they may have been robust, nothing lasts forever.

The Dynatek unit on the bike is the DS2-2

My son got these coils. Not sure if they are right, and its too late to call Dynatek. Who the hell knows if they are right. Like I said, proud of my sons, one is a gazillionaire from a tech endeavor loosely associated with Facebook. He actually gave me back the $500 I spent on the carbs. Left it under my tool kit after he left my house after sunday dinner with his fiance. Nice kids but they have too much testosterone!

I highly recommend the Wired George relay setup for voltage to the coils. It will give you full battery voltage at the coils. Just follow the link below.

www.wgcarbs.com/index.php/using-joomla/e...-categories/89-coils

hardrockminer wrote: I highly recommend the Wired George relay setup for voltage to the coils. It will give you full battery voltage at the coils. Just follow the link below.

www.wgcarbs.com/index.php/using-joomla/e...-categories/89-coils

Thanks, but not really interested in that setup or spending my or my son's money on it. I want to keep this as simple as possible and as stock as possible in most ways.

Thanks.