$%#*# CARBS! I miss my PODS!!!!!

Ok. I don't really miss my pods. But I figured the subject line would get some attention from some experienced folks.

I took my carbs off my XJ and cleaned them up.

Someone had painted the tops of the carbs black. So I used the wire wheel on my bench grinder to remove the paint. The chrome is not perfect, but sure looks a lot cleaner than the crappy, peeling paint job that was on there.

Removed and cleaned all the jets (well, main, pilot and needle jets), polished up the slides (didn't need it, though) and ensured all the enrichening circuits were clear (they were!!!). That part was easy. Putting the dang things on is a different story!

After messing around trying to figure out the easiest way to do this, I removed the boots from the air box and installed them onto the carbs (eye-balling the little alignment tabs to be at the 12 o'clock orientation). Then I fitted the carbs into the intake boots on the engine. Now I'm finaggling the air-box boots back into the air-box, starting with the two inner ones first. I had just started this part when I got interrupted and had to quit for the night. I went out an hour ago and turned the heaters on in my shop and will try to finish this up in a little bit.

Just thought I'd see if anyone had any tips to make this easier than it appears to be. Thanks!

 

On the 550s, the airbox mounting points are slotted so the airbox can move rearward a few CM.

I usually yank #1 and #4 right out of the way, leave boots 2 and 3 installed on the airbox, and "rotate" the rack into place, worrying only about the intake manifolds and just letting the carbs mash the two inner boots whichever way they want to. Once all of the intake manifold clamps are tight, then I finagle the two inner boots into place and finally, reinstall the outers.

It helps if everything's warm; if the boots are stiff, boil them (yes boil them, in water) gently for about 3-5 minutes. They'll stay flexible for quite a while.

 

Which XJ are you working on?
The airbox should stay in the bike with the tubes in it. There is no need to remove the airbox and tubes to get the carbs in or out. The airbox will unbolt from the frame and slide back far enough to slide the carbs out between the intake and airbox boots. It will go back together the same way. If you have the airbox out now, go ahead and put the boots back in and re-install the airbox. Slide it back in the frame and work the carbs in. It is tight so be prepared to cuss and wiggle the carbs. A little silicone spray on the boots will help.

 

That sounds a bit less clumsy than the way I'm doing it. I left it pretty close to done, but if I can't get it quickly, I'll try your method. And I'll definitely try it next time from the get go. Yes, I did slide the air box back via the slotted mount. Thanks.

 

Hi,
On my 750 I pop all of the airbox boots back into the airbox with just the lip of the boot that normally attaches to the carb poking out and slide the airbox as far back as possible also.

With the boots in this position the carbs slide into position in front of the inlet manifold boots without any extra mechanical pressure and with the judicious use of a large flat screwdriver the boots can be popped back into place pretty easily after the carbs are pushed into the inlet manifold boots. They slide out just as easily when pulling the carbs out too of course.

The boots still have to be malleable but after putting the carbs in this way and then, like bigfitz, finagling the airbox boots back into place it is so much simpler than trying to force the carbs into position.

Since I've done it like this at least 5 times now it seems easy to me and in comparison the strongarm method makes the job a gruelling saga of despair, IMHO of course.
Now I don't think of doing the carbs as a major exercise because of this method of removal. As long as I'm careful popping the airbox boots back into place I don't foresee any problem continuing with this method either... at this point.

 

It wasn't very difficult. Just a little tedious. I forgot I already had them about in last night when I got distracted.

I may have been unclear, I did not remove the air box to do this. So...the carbs are cleaned and back in the bike. I should have my new fuel shut-off valve tomorrow in the mail. Still have to drain and change the oil. Once I get it functional I will figure out paint and resolving my seat issue and I should be ready to fire it up and see how it runs.

 

now that you got things figured out. can you order us a heatwave. my bike is starting to feel lonely.

i should get off my butt and do what i gotta do. but NOT looking forward to flushing the brake and clutch out. i'm leaning towards a new motorcycle this year though. not wanting to do any work if i don't keep the bike.
:lol: