Won't Start

I am not sure what all I need to get for airbox boot replacement.

This site:

http://www.powersportspro.com/pages/...2%2f5602710015

has tube outlet in and side, which looks right.. I am not sure about RING OUTLET TUB CL, SIDE.

Also number 11 on the fiche is no longer available, which of course is the worst shape of them all...

Anyone have any idea on what air box boots I need?

I had a go at it tonight..no luck.

I unbolted the box from the frame, slipped some sylglide on the new intake boots, and the old airbox boots. I got the carbs to slide into the new intake boots, but for some reason the air box boots will not go over the carbs.

Is there such thing as having the carbs pushed in to much? My air box boots look okay, but I can't really tell if they need replaced..

I tried like hell to push back on the carbs to see if they would slide into the airbox boots but no go. I was so frustrated, I ripped everything off and am thinking about getting all new air box boots. Soooo close!!

[Octain]

Well I got the airbox on nice and tight last night. Only took 3 hours

NOW, the carbs are not even coming close to fitting. I have brand new intake boots which are stiff, and I am using the old airbox boots.

Any suggestions on which way to attack this?

I had a 82(or was it an 81?) E and trust me, it dont seem like they go in that tight little space but they do. The air box must be unbolted and just sitting in place.
They are very hard to get in there, almost feels like you're gonna bust something. Ya really have to force em. Had to apply so much force had to have my son hold the bike so it wouldn't tip over.
But be damn sure there is nothing in the way and only use your hands( no pry-bar) so you can feel if you're hitting anything solid.
I had new intake boots but old air box boots. One of the intake boots folded(for lack of a better word)around the carb but the others were in place. I had to remove em and start all over.

Seriously, it's a PITA.

Your model is slightly different but..... you DON"T want "airbox on nice and tight" - you want it just hanging in there (not bolted) and pushed to rear as far as possible, move wires, loosen fender, etc. anything that gives you an extra 1/4 inch .

Yeah, I will loosen the bolts holding the box to frame tonight and give it a go.

[tom203]

Well I got the airbox on nice and tight last night. Only took 3 hours

NOW, the carbs are not even coming close to fitting. I have brand new intake boots which are stiff, and I am using the old airbox boots.

Any suggestions on which way to attack this?

Your model is slightly different but..... you DON"T want "airbox on nice and tight" - you want it just hanging in there (not bolted) and pushed to rear as far as possible, move wires, loosen fender, etc. anything that gives you an extra 1/4 inch .

Use some grease. I use plumber's grease, see my review in the Product Reviews section.

Well I got the airbox on nice and tight last night. Only took 3 hours

NOW, the carbs are not even coming close to fitting. I have brand new intake boots which are stiff, and I am using the old airbox boots.

Any suggestions on which way to attack this?

[BigD_83]

FWIW, I put my carbs in and out from the right side on my 650. Soft boots and teflon spray make it less ornerous. It's still a PITA on the smaller bikes though.

P.S. +1 on airbox first, then carbs.

[Octain]

Airbox first. It's a b1tch, but it works..

[tom203]

Got the carbs. rebuilt with fresh o-rings, gaskets. Just got done installing new carb intake boots and o-rings as well.

Now I am putting her back together. Is it best to install carbs first, then air box, or air box then carbs? I am having a heck of a time trying to get the airbox back on.

Will post pics. later.

I'm pretty sure you want to get airbox in and back as far as you can and then get carb rack in from left side- it ain't fun!

[cowboyup3371]

Put your airbox in first and pull it back far enough to get the carbs in. You may have to loosen up the rear mudguard to do so.

Got the carbs. rebuilt with fresh o-rings, gaskets. Just got done installing new carb intake boots and o-rings as well.

Now I am putting her back together. Is it best to install carbs first, then air box, or air box then carbs? I am having a heck of a time trying to get the airbox back on.

Will post pics. later.

[Nessism]

Please take a few mins and read though the carb rebuild tutorial. It details the correct way to measure float height (you must hold up the float if the float needle tang spring won't support the float under it's own weight. Also, consider replacing the float needles if they won't. The tutorial also detail how to get the diaphragm boot to stay in the groove without using grease or any foreign material.

Good luck

You did see this right? from Basscliff's. doublecheck, cuz setting float heights is confusing. Wait till some pro chimes in. But yes, you bend tab




http://members.dslextreme.com/users/...eight.html#A02

Thanks. Yeah I saw that, still kind of confusing. I will take a look again tonight.

[tom203]

You did see this right? from Basscliff's. doublecheck, cuz setting float heights is confusing. Wait till some pro chimes in. But yes, you bend tab

http://members.dslextreme.com/users/bikecliff/images/carbspec_float_height.html#A02