Air box to carbs

HOTWAX · June 10th, 2018, 01:09 PM

So today I cleaned the carbs on my 2004 (wouldn't idle at all). So I cleaned them and in reassembly I cannot for the life of me, get the air box boots to fully seal on the carbs and when I do the other side doesn't seal. I just cannot get them to seal properly. If I get suggestions the would be freaking awesome.

Carytowncat · June 10th, 2018, 02:03 PM

I just had a similar issue when reinstalling the carbs on this one. In fact if i tighten the clamp the boot slips off, but it's a hose clamp and not the stock thin one so not much i can do about it.
I often press one in good and tighten clamp then do the other.
Good luck!

Triple Jim · June 10th, 2018, 02:23 PM

Doing the battery box separation mod fixed that for me.

DannoXYZ · June 10th, 2018, 03:51 PM

Do both sides evenly at same time.

Before airbox, make sure you have hose clamps on tight on boots on engine.
Then make sure clamps on boots on carbs are tight.

That way, carbs don’t move and wiggle when you put airbox on.

Cgswss · June 11th, 2018, 01:53 PM

My first thought is that you are not installing the boots the way they came out. The boots have a couple of small curves in them to make up for the distance between the ports is different on the head then on the carbs.

It’s too late for the easy way to solve this. You should have made marks for “top” on each boot befor you removed them.

So, take the carbs all the way off. Then watch carefully as you turn each boot until you can hold a straight edge across the open ends and the outside and inside of each tube all touch the stright edge

June 10th, 2018, 01:09 PM	#1
HOTWAX ninjette.org newbie Name: Grant Location: Kendallville Join Date: Jun 2018 Motorcycle(s): 2004 Kaw ninja 250 Posts: 2	Air box to carbs So today I cleaned the carbs on my 2004 (wouldn't idle at all). So I cleaned them and in reassembly I cannot for the life of me, get the air box boots to fully seal on the carbs and when I do the other side doesn't seal. I just cannot get them to seal properly. If I get suggestions the would be freaking awesome.

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June 10th, 2018, 02:03 PM	#2
Carytowncat ninjette.org member Name: Nick Location: Richmond Join Date: Feb 2014 Motorcycle(s): Ninja 250R and BUELL Blast Posts: 28	I just had a similar issue when reinstalling the carbs on this one. In fact if i tighten the clamp the boot slips off, but it's a hose clamp and not the stock thin one so not much i can do about it. I often press one in good and tighten clamp then do the other. Good luck!

June 10th, 2018, 02:23 PM	#3
Triple Jim Guy Who Enjoys Riding Name: Jim Location: North Carolina Join Date: Jul 2016 Motorcycle(s): Ninja 250 Posts: A lot. MOTM - Oct '18, Aug '17, Aug '16	Doing the battery box separation mod fixed that for me.

June 10th, 2018, 03:51 PM	#4
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Do both sides evenly at same time. Before airbox, make sure you have hose clamps on tight on boots on engine. Then make sure clamps on boots on carbs are tight. That way, carbs don’t move and wiggle when you put airbox on.

June 11th, 2018, 01:53 PM	#5
Cgswss ninjette.org member Name: Craig Location: Port huron Join Date: May 2018 Motorcycle(s): 250 ninja Posts: 19	My first thought is that you are not installing the boots the way they came out. The boots have a couple of small curves in them to make up for the distance between the ports is different on the head then on the carbs. It’s too late for the easy way to solve this. You should have made marks for “top” on each boot befor you removed them. So, take the carbs all the way off. Then watch carefully as you turn each boot until you can hold a straight edge across the open ends and the outside and inside of each tube all touch the stright edge