airbox boots don't fit

after giving my carbs a good cleaning, I put them back on and now the seal looks like this. Is it normal? I'm pretty sure it's making a good seal, it just looks like it should be shoved on a bit more, but it won't go.

The alignment tabs are at the top of the boots, so I've got them the right way up. I did take them off completely so I may have switched them around, but they're all the same right?

 

Have you tried moving your airbox more forward? The "+" screw goes through a slot in the frame, so it can shift fore and aft.

These boots do shrink as they age. BigFitz has recommended boiling them to make them more pliable, I'm not sure if they would lengthen at all. You may just need to get some new ones.

They are all the same, the ones on the other side of the carbs are unique.

 

It's on there, but just barely.

Here's how I re-install the airbox-to-carb boots:
Boil a pan of water
Remove from heat
Toss in boots
Let soak about 10 minutes
Remove one boot
Install onto #3 carb
Tighten clamp
Install into airbox
Repeat for #4, then #2, then #1

This will allow the rubber to soften as well as expand making installation easier.

The airbox-to-carb boots are interchangeable. They may have a "memory" from being on so long, but the hot water soak will allow them to return to shape.

 

I had the same problem... tskaz's solution may help some but the weather and any fluid (gas) that may have settled there for any reason will likely shrink the boots on the bottom. Might just be easier to get a new set, IIRC they're cheaper than I thought.

 

My solution is to keep my hot airgun handy. If a boot is too hard or short or whatever, and needs to be stretched a bit, some careful work with the heatgun works wonders.

Best of luck to you.........

Dave Fox

 

On my bike I have the same problem - the forward side of the airbox seems to have relaxed inwards a bit over the years. Being plastic with 4 big holes in it and not being supported internally, its no surprise it does this. The inner two carbs present the most trouble to connect properly.

Get a helper, then remove the air filter. Have the helper reach inside the airbox and push the forward side of the airbox forward as you connect the boot to the carb, one boot at a time.

Worked great for me, it will give you the good connection you need.

 

Thanks for the suggestions. good to know I'm not crazy. I'll try the hot water trick tomorrow.

My airbox seems to be more or less flat, and it's all the way forward. Might just have to get a new set. we'll see ..

 

I am having the exact same issue!! Literally just walked in from the garage to check the forum to see if anyone had this problem. I will try boiling the boots tomorrow. Let us know how they turn out for you.

 

http://www.xjbikes.com/Forums/viewtopic ... boots.html

 

+1 on the hot air gun

 

Someone else has a post about Rubber Renue which might be worth a look. I've never replaced those rubbers and they are a pain to put back on (and not getting any easier) but they do usually go back on. If they don't, I have often found that somewhere out of site the boot isn't sitting quite right.

I certainly wouldn't want to have it sitting 'not quite on' for long though as I expect they would take a set and never fit properly again. That usually involves pushing the airbox as far forward as possible too.

 

7 dollar heat gun from harbor freight worked mint for me. I did it in the freezing cold to boot.

 

I had to get a new set when I did my valves... I boiled the old ones, but didnt use them right away. When I tried to reinstall the carbs a few days later, the 4th boot wouldn't fit at all. It looked like it had shrunk, tried to re-boil but had no luck.

I guess what I'm getting at is if you boil 'em, put them on right away! Also, new ones were a lot cheaper than I though from local bike shop...

 

Ok, boiled my boots and they turned out great! Nice and pliable. # 2 still had a bit of a gap at the bottom, so I loosened the boot clamps on the engine side, propped a wrench under the carb bodies and lifted them a bit so they were tilted up a little. Once I did that, they were all snug. I tightened all the clamps on the intake side first, went back and tightened the engine side clamps, and removed the wrench. Like a damn glove! And the world was right again.

Now I go to prepare to start my bike up and quickly realize that O'Reilly sold me the wrong spark plugs. Jeez.

 

The AirBox should have a pair of 10mm Bolts ... On top ... Right near the Securing Point for the Fuel Tank Bolt, ... that will let you move the Box front or back ... as needed.

Installing the Boots is made a bit easier if you:

Increase the Inside Diameters of the Boot Holes ... ever so slightly.
::: ( Tape 320 Grit to a 6" long section of Closet Rod, ... Sand Holes ) :::

Sand the opposing "Walls" of Locking Groove Surfaces and the Outside Diameter of the Boot.
::: ( Glue 320 Grit to BOTH SIDES and the EDGE of a Wooden Paint Stirring Stick ) :::

Re-sand the whole works with 800 and 1000.
Clean.
Apply Car Paste Wax to the Box and Boot Grooves.