Z1OwnersClub GB

What is the best way to install the airbox rubbers and carbs as it is all a very tight fit. Is in airbox in minus rubbers then carbs the rubbers and connect up assuming that the head rubbers are already mounted in the first place.

deka wrote:What is the best way to install the airbox rubbers and carbs as it is all a very tight fit. Is in airbox in minus rubbers then carbs the rubbers and connect up assuming that the head rubbers are already mounted in the first place.

You won't get the rubbers into the airbox once the carbs are in if it's all there as they are clamped in place, never mind being able to get them in there at all. I put the air box in, slide the carbs across from the RHS of the bike above the airbox and carb rubbers. Push the airbox side of the carbs down so it deforms the airbox rubbers then tilt the front of the carbs down by pulling back and you should be able to get them to slide down and locate in the head rubbers. You won't do it in one go, and you may need to lever the carbs back to get nos 2 and 3 to fit. I have a screwdriver bent at nearly 90 degrees and the end filed blunt which I then run around the carb rubbers to seat them. If the head rubbers are being a pain, you can get them nearly there and pull the airbox rubbers on, sometimes that gives some extra clearance.

You need all the clamps on too, but the airbox ones pulled back towards the airbox, and once they are in make sure you can get at all of the head rubber screws and they aren't fouling the ribs on the carbs.

Strangely, every one seems slightly different, but they do go it just takes patience.

I find a bit of warmth from a hot air gun can help keep the rubbers pliable . Not to much though.

Many thanks

If the airbox rubbers are supple the carbs will go in easily. If not it will be difficult. Try warming them with a hairdryer, or replacing them with new.

Thanks Nigel all the rubbers are new so nice a supple. Just wondered if there was a best practice at putting them tog eat with space being a premium

deka wrote:Thanks Nigel all the rubbers are new so nice a supple. Just wondered if there was a best practice at putting them tog eat with space being a premium

I should probably video the process as I do it quite a lot and just did it last night.
Ideally get your throttle cables connected before you fit the carbs, it is possible after but very fiddly...
Basically, place the carbs in position (lined up) above the rubbers. The rear rubbers will need to be pressed downwards. Slowly push down at the front (inlet) and get the front of the carbs into the inlet rubbers. Then gently push down and forward to get them in place.
You should now find that the rear (airbox side) rubbers are squashed down. You should be able to use your fingers to pull each one into place around the carb mouth.
Once located, check that the airbox ribbers haven't pulled away from the airbox plate that holds them in to the airbox. If they have you can usually push them back with your fingers or a non-sharp implement.
Then, pull the carbs backwards towards the airbox slightly - this ensures that the rubbers are correctly located. Fit and tighten the airbox side retaining clamps. Push the carbs forward so they are located properly on the engine side and do up the clamps.

Hope this makes sense.