Trouble installing air-box boots on Carbs

[Hemp]

I spent six hours Sunday trying to get the rubber boots on my air-box to fit snug over the carb manifolds. It was my most frustrating motorcycle experience ever. I was unable to get all the boots over the manifolds and clamp them down.

Once I got one boot to fit over the carb it would simply pop off when trying to get another boot on. I even went as far as grinding/forging my own metal "spoon" like one would use on tires.

I'm out of ideas and can only guess that the box may have warped from heat or something; however it looks good at a glance and the boots look practically new.

Has anyone else had a hard time clamping their airbox on the carbs? Is warpage a likely possibility. I'm tempted to drop $50 and get another used box but have my doupts. Any ideas?

1994 Suzuki Katana 750 California model, my Baby.

Thanks

Hemp

[Kfreak]

You have to work them on from one side to the other. Install them with the air filter out, that way you can stick your hand inside the air box and work the boot around the throat of the carb.

[VifferJim]

You have to work them on from one side to the other. Install them with the air filter out, that way you can stick your hand inside the air box and work the boot around the throat of the carb.

Bingo!!

[GytRDunKat]

ayup, air filter out.

[Black_peter]

Though I haven't tried it Md (who has taken apart more then a few carbs) says the best way is actually put the airobox on the carbs then put the carbs back on the bike..

[md86]

Indeed .ONLY way I could ever get it to work for me . That way it's also easier to make sure the boots stay put whilst tightening the other clamps . I ain't taken the airbox off the carbs since last time I replace the fuel lines (been a coupel years) . I HATE messing with the airbox .

[Trackerrrr]

Though I haven't tried it Md (who has taken apart more then a few carbs) says the best way is actually put the airobox on the carbs then put the carbs back on the bike..

+1 That's the only way I've ever been able to get the carbs and airbox back together right on the bike.

[steves]

Make sure the clamps aren't messed up either. I've seen some pretty bad ones.

[philwecksr]

Man, I am NOT jealous of you pre98 owners... My airbox just slides right on with little to no effort...

[Dankid]

Wow, deja vu. I went throught the same exact ordeal yesterday. I took off the air box to put in a new filter and couldn't get the boots of the air box around the carbs at all. After 2 hours of failed attempts I decided to take off the carbs and was able to get the air box on in no time. My clamps are in pretty bad shape though which didn't help. Can those clamps be replaced with the type you can get at the home depot plumbing section or is it a strictly oem replacement?

[ctandc]

I never had a problem with my pre....even before the post 750 swap.

I always took a small bit of rubber grease on the tip of my finger, spread it around the inside of the airbox boots, kept the filter out, loosened the clamps and they always went right on for me.

I did work it either side to side or bottom to top....not all at once..

[Dankid]

I always took a small bit of rubber grease on the tip of my finger, spread it around the inside of the airbox boots, kept the filter out, loosened the clamps and they always went right on for me.

I grease it all up and loosened up the clamps all the way and still couldn't get the air box on. A few of you keep mentioning to put the air box in without the filter but the bars that sit behind the air box will no let you put the air filter in or take it out if the air box is connected to the carbs. I'm confused. I have a 600 so maybe it might be different on the 750.

[chemomche]

take the carbs off and the air filter off
then you can easily put your hand in
(i had problems with my carb and put off and on the air filter box more than hundred times,now can do it with eyes closed

[kevin2502000]

+10 on airbox on the carbs before you install it.

[md86]

Man, I am NOT jealous of you pre98 owners... My airbox just slides right on with little to no effort...

Yeah , but I can STILL change my jetting quicker than YOU can , AND have the carbs SYNCHED before you're prolly even halfway there .