XJ-650 Hitachi Carb Fuel Transfer Pipe O-rings

I'm replacing the o-rings on the fuel transfer pipes between the carbs on my XJ-650. I've got some 5mmx2mm and 6mmx2mm viton o-rings that I'm trying to use but I'm having a devil of a time getting the pipes with the new o-ring back into carb. I tried using some synthetic oil to lubricate them but still didn't work. Any suggestions for an easy way to get these transfer pipe fittings back into the hole in the carbs?

 

To start with my friend, you never use oil on rubber. Possibly solid Silicon or maybe no, best would probably be the solid silicon in the tube. When I was in the water business I would always use that on the big O-rings on Carbon filter housings where the top would screw onto the lower housing on the O-Ring. That way they would always come apart easily when I would have to replace the carbon filter. Thats about the only thing I can think of but I am sure there are others here in the room which can probably come up with better answers than mine. There are some pretty Smart Cookies in here as to say. 81' xj Yamaha 750 Seca, grunt007, Mi.

 

When I did mine I had some dielectric grease handy and I know that stuff is super slippery(get some on yer hands and wipe off with a rag)Im not sure if its bad for the O ring or not somone will say wether it is or not but damn did it work good had to push a bit but it went.

 

I use Brake Fluid.
Can't hurt anything.
Cleans-up real easily.

I have also used:
Marvel Mystery Oil
Synthetic Waterproof Grease (Bicycle Shop)
Filippo Berio Extra Virgin Olive Oil
Palmolive Dish Washing Liquid.

 

i hear the originals were "D" shaped and not around anymore.
viton is what you want, a few of mine have trimmed themselves when i knocked them in. just get a bigger hammer, they'll be fine

 

Petrolium based oils cause rubber to swell and thus they wont fit properly.

 

Aw Ha, I see everyone is starting to wake up in here, how bout that. You see what I said, be patient and there will be plenty in here to give help on the issue. I still disagree with either greese or oil on rubber. The Die electric I am not sure about. I have used it on Spark plug boots ect. but they are an article which we don't bother to much about changing when the cables start arching ect. Nope, I'm not convinced, I'll stay with the solid Silicon in the tube. One of the best products I've ever hooked up with. My wife was complaining about the Vegetable bin in the refrigerator hanging up when you pulled it out (plastic). I put a little bit of the solid Silicone on the sliders, next thing I heard was KABOOOOOM! I came out in the kitchen and here lay the vegetable bin on the floor! My wife pulled it out and I forgot to tell her I put the silicone on it and a little pull and it came out and hit the floor before she knew what happened. Now I also have it on the kitchen sliders as well. )))) 750XJ Seca, 81, grunt007, Mi.

 

This is at the crux of the matter. The originals were indeed "D" shaped, although even Yamaha now supplies normal, round-section o-rings as replacements.

Viton rings are the recommended replacement, but stiffer than the other alternatives.

 

I did a rehab-job for a customer who sent me all "Dealer-bought" Parts for the job.
The Fuel Gallery Tee O-rings were round, viton, individually bagged, Logo'ed, bar-coded and priced at $4.95 each.

When I split one pressing the Fuel Tee into the Gallery Bore; I bought a half-dozen identical O-rings from True Value Hardware for $1.74 .

There are sliding drawers with a selection of every imaginable O-ring in the Plumbing Section at True Value.

 

Thanks! Sounds like I need to get the synthetic oil off those puppies. I thought maybe the diameter of the O-rings was too big, maybe a 6mm x 1.5mm would go in easier. I did get one in with a press but it shaved some rubber off the O-ring and it was a really tight fit. Can't imagine trying to rig up a way to press all three in without breaking something. Didn't want to use to much force less I crack the metal around the hole. The ones I'm using are viton and kinda stiff. Anyone know exactly what size O-rings came on it? The groove in the fuel pipe is a bit over 6mm outside diameter. I figured a 6mm I.D. O-ring should be about right.

 

I think the O.D. is right on 1cm (one-centimeter).

 

I think the O.D. is right on 1cm (one-centimeter).

 

Hey RickCoMatic! Is that 1mm (one millimeter) c/s (cross section)? 1 cm may be a bit large.

 

Circumference.
Outside -to- outside.
1 cm.