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Re-installing Carb bank

F

freefalldl

Guest
Guest
I'm no mechanic... I'm in the middle of a top end overhaul. Head back in and for the life of me, I can not get the carbs back in and connected to the intakes and the air box. Removal was easy because I had the head removed for the valve job/re-surface. The Kawasaki shop manual is not specific to technique. Any tips are greatly appreciated.
 
New carb boots (from carb to airbox) makes it easier.. If they are not that old, heat them up (hairdryer). You just have to force them into the boots on the heads, them work on getting the other boots on. Just got to muscle them on! I put the cables back on once the carbs where part way in, just to make it easier for me. Dave Muir 1980 LTD1000 - Rocket 1999 Concours - Rocket II 1997 Dyna - wife's CT-COG #3649 Merchandise Czar
 
+1 on what Dave says plus use plenty of silicone spray on all the boots. Bring the rack in from the left side,attach the cables before you put them to far in, Just ignore the air box boots till you get the carbs into the intake boots then you can work the
 
I just pulled, cleaned and re-installed my carbs. The boots where 8+ years old and although I was successful in getting them back in (a major struggle) they lost all flexibility and I could not get them to seat on the carbs. New boots are the only way to go. I would suggest as Norm stated you re-install the carbs from the left side and re-attach the cables before you get the rack in. This might require another set of hands, but it is not impossible to do by yourself. Once you have the cables on (correctly!) you can then position the rack on to the engine boots and do not tighten up the clamps. Remove the two bolts holding the air box in place as this will give you a smidgen more room. Starting with the #2 air to carb boot (and the boots are different! Kawasaki part #14073-1225 fits duct #2 and #4 and PN#14073-1224 is for #1 and #3. With the rack in place on the engine boots place #2 in between the carb and the air box first. Squeeze the damn thing into place by working the airbox side in first from left to right into the airbox, then work the carb side over the carb. I used a pair of long handled bent tip needle nose pliers to work the boot over the carb. The rubber "seam" should be straight up and down. Make sure the boot is seated on the air box properly. You should be able to rotate the boot if it is out of position. Also do this with the springs on over the boot as they are a total pain in the ass to get on once the boot is in place. Then work in #3 form the right side following the same procedure. (it is a pain in the ass but soooo much easier with new boots. #1 and #4 will be cake in comparison to #2 and #3. Once you have all the carb to air box boots in place bolt up the air box and wiggle the carbs into place so the carbs to boots are seated then tighten up the engine to carb boots. Here's a link to Dave Morrows site that might be helpful http://www.ldrider.ca/techpages/carbremoval.htm and I've already given you the part numbers and here is a link to Murphs site for buying them. http://www.murphskits.com/catalog/product_info.php?cPath=1_94&products_id=218 The $48.00 is worth not having to wrestle the old ones in just to find out they will not seat like mine did! Best of luck! AKA "2linby" That's 2-lin-by folks! Northwest Area Director COG #5539 AMA #927779 IBA #15034 TEAM OREGON MC Instructor http://community.webshots.com/user/2linby http://tinyurl.com/njas8 (IBA BunBurner Gold Trip) http://tinyurl.com/lwelx (Alaska trip)
 
What worked for me was to fold the airbox boots on themselves and use zip ties to hold them (as suggested on the Concours forum). I had the two bolts of the airbox removed to make it easier to wiggle it as I was sliding the carbs in. Once they are in place, just snip the zip ties and the boots should fold out and wrap around the carb intakes. Ez, pz. My bike is an '03 and the boots had plenty of flexibility left. Oh, and make absolutely sure that you got the throttle cables right before you go ahead and tighten everything (don't ask me how I know!) Vlad
 
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