Yamaha Virago part 6, refitting those b****y awkward Carb Inlet Rubbers
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- čas přidán 16. 06. 2017
- The absolute worst bit bar none of working on the Virago, refitting the carb inlet rubbers in the frame airbox to the carb tops, I was asked if I had an easy method for refitting them, I didn't at the time I read the question and have struggled with it more times than I care to think about. BUT! I happened to have this exact job waiting so I put some thought into it and came up with this.
It doesn't make it a doddle, but it certainly makes a real time consuming pig of a job much much quicker and easier.
Hello all. In case anybody is reading this, having difficulties getting their carb/carb boots back on, here's what I did...
Upon cleaning my carbs, I reinstalled the rearmost (aft, for the nautical types) boot into the correct position from the bottom up. With nothing in the way, the boot slides in pretty darn easy. With a bit of elbow grease (and swearing) I massaged the carburetor into place. At this point, the carburetor was in place, both lower mounts were in mounted firmly, and the rear boot was in position. After this, I refitted the forward boot with relative ease.
If I were to do this all again knowing what I know now, I reckon the job wouldn't take me more than an hour single-handed.
Mate what side did you put your carbs in from ? I have tried both methods and I'm still really struggling..
@@morkus17 mine went in and out on the right side but book says left...
Thanks man... I did the folding thing only at the bottom, with zip-ties, to try and get it through the airbox. Gonna try the 2 rope trick tomorrow. your previous 2 vids on the 535 were brilliant. first time ever opening, cleaning and repairing a carb was on my virago 400, and had her running today, without the airbox pipes, and runs a lot smoother now on idle and free revs better then when I bought it. cant wait to get the pipes back on and go for a spin
Bob van Laake Fantastic, glad to hear they're useful, that's why I love doing the videos. Those carb inlets and airbox were designed by a sadist! Lol
Great idea. Love it!
I got the boot started with the string, however I was unable to get the last little bit necessary to set the boot over the carb. After much aggravation, I decided to take a bicycle inner tube and fold part of it up, stuff it over the top of the boot and the rest inside the “air box”. I inflated it a little bit at a time, making sure not to pop it and... VIOLA! Worked like a charm! With the pressure on top of the boot, I was then to manipulate it down on top of the carb. Repeated same process for front boot.
Great thinking.
Ingenious.
Thank you for the video. The string was handy but so was the suggestion below to install the rear intake rubber before the carb. I then got the carb in on the the two inlets below and the one rear rubber to the air box, for the forward rubber I used your string idea but didn’t unwrap the top string until I had the bottom end fully down on the carb.
I'm glad it was useful. I don't know what Yamaha thought they were doing with that design. A fully open top air box would have made more sense. They could have left a cross brace and retained frame rigidity. I've struggled with it so often in the past with my old one. (The one in the review video I did) and can't believe that was the first time I'd thought to use the string to help it through.
spidiq8 trying to get these back in was driving me so crazy that I took a break and a CZcams search. Thank you for making this. I agree it’s a silly design that could easily been made a whole lot better. The bike has been off the road for 10years but got it back together and started tonight. Still need to finish painting a tank and balance the carbs but otherwise almost finished.
@@irishflyer6377 That's great, another one back on the road is good and you might even get some good dry riding days before winter sets in.
Never in all my days have I seen such an awkward job. Plenty of foul language, skinned knuckles followed up by lots of aggressive pointing with more bad language but we got there in the end.... Ohhhh I need a cup of tea....
They're not the easiest are they. I'm sure many mechanics would love to have a chat with the designer. 😁
Bloody brilliant m8
Nice man
I struggled for 2 hours to get mine back in place haha. Such a weird design. I’m tempted to cut the top of the air box and add a hinge if I ever have to get back in there
Take care if you do as it's a structural part of the frame.
If I had another I'd make a y piece inlet manifold and fit a larger single carb and side air filter.
Thank you for this video. I see now very clearly that the air boots are supposed to be soft and easy to fold. I have skinny hands and managed to get the air boots in, but the rear one has probably shrunk because it doesn't fit over the carb anymore... Not happy about this, but i am glad to find out that ordering new part will not be a waste of money.
They should be flexible. If yours have hardened which does happen with age and use but they're not cracked you can boil them in wintergreen oil to restore them somewhat.
It's smelly so ideally do this outdoors on a camping stove.
@@spidiq8 Yea, thank you :) I saw that on google.
While trying to accomplish this feat; i kept imagining the worker who's job it was at the Yamaha assembly plant.
Chances are they had some clever assembly device or they'd have had the design changed quickly.
Here is my trick. Grease the boot. Fold the boot into a plastic tube of about 5cm. insert down until it is stopped by the carb, remove plastic tube leaving boot in place. Step one is done. Step 2 is to use a no sharp hook of 8 inches (i used brake line hose) to pass between the boot and the air box body. While pulling down the top of the boot with the hook, manipulate the bottom of the boot with plyers to fit the carb.
I'd say be sure to use silicone or red rubber grease and be careful with pliers as you don't want to damage the seating faces.
done your string trick got them both through but my problem is i cant seem to get them to sit ontop of carbs in order for me to tighten them up why
Is it because the boots have hardened and you're having difficulty moving them into position or some other reason?
Finally got after 3 days of trying, bleeding, confused, and mad 😡 lol well today I tried this and it took me 15 minutes for real!!!! I put a little grease and smeared it on the second lip, put the carb in then put joints on intake and carb inlet in joints. Took the boot by hand folded like you did no string got it to get past the one big lip then from inside the air box I pushed in where the tag or tab sticks out on the second lip pushed that through with ease. Grabbed some curved needle plyers and pulled down on the back and the boot slipped right on. Did the front the same way.
@spidiq8 it worked :) I was so relieved!! I edited my comment and it took the heart emoji off from you now I'm sad lol 😂 no I'm so happy now!! Thanks for the tips and all your videos on the Virago!!!
Lol, there you go, one heart emoji back for you.
Do be sure if you use grease on any rubber components you either wipe it off immediately after or use one formulated specifically for rubber such as Silicone grease as regular grease can degrade rubber.
@@spidiq8 yup I used a chassis grease and wiped it off too
@@spidiq8 thanks for the heart emoji 😂
@@spidiq8 it was bel-ray grease
Hi, great videos. Why the wide flange on the rubber tube anyway. It does nothing. I just trimmed it down by half so there was enough ridge to fit the clamp on and keep it in position.it made it a lot easier to pass through the air box. Also a bit of washing up liquid on the rubber helped. Still had to use bad language though.
Good question. The only thing I can think of is that it might be thicker there because it's a stress point where cracks and air leaks can easily occur?
I used WD-40 to lubricate the sides of the inlet rubber and then use 2 srewdrivers to lever it down. i only lifted the inlet rubbers one step up so I only had to lower it one step. Still took maybe 15 mins.
Lubrication would certainly help but be sure to clean off the WD40 thoroughly as that isn't good for rubber with long exposure, you could always use silicone grease which is designed for rubber. As you say though, they're awkward no matter what.
Hey man! Thank 4 share !
I have prolem with my carb
I"ll remove and replace single carb sr400 for my virago xv 400 , so what do you think? That will be ok?
Help pls
Glad it helped you. Thanks.
Apologies I thought I'd replied to another comment.
Theoretically yes but it depends on having sufficient fuel flow and making a suitable intake manifold.
I like the idea of using the string to hold it! It was still hard on the forearm to get in there squeezing the rubber together. It took 5 mins to get them in after nearly an hour in the morning of swearing and cutting my forearm into pieces! I feel chuffed my idea made it on CZcams!
I think when the bike gets stripped down in the winter iam going to modify the air box so I can get the top off.
simon moore That was version 2, after reading your question I just knew there had to be a way to do it. I tried zip ties but the bugger kept popping open. I always said if I'd kept mine id have stuck either a single or twin upright carb setup on with a side mount filter. it's the one thing I detested of thr original design, looks neat but it's torture to work with. Careful you don't damage the frame integrity if you cut it though.
Iam looking at removing the section above the carb inlets, manufacturing a new plate and just tap some holes to secure. A thin rubber gasket should seal it.
There seems to be a lot of room between the tank and the box so I don't see any problems with that.
As far as structure goes there will be more then enough of the orginal box to keep its strength.
Well I'll see how the strip goes in the winter. I'll be happy enough to get on the bloody thing once my replacement diaphragm and Cylinder assemebly get here!!
simon moore That should work, there's a lot of box structure there.
do an update on the bike! its been almost 7 months and i'm curious to see the end result :)
Jonathan-David Pieter Heij Sadly I can't, I wasn't able to work on it for several months due to family related things and the owner was champing at the bit to get it back, I did want to sort the fuelling problem which I'm sure was electrical and think was a relay, the wiring had been unsympathetically attacked previously.
I was also going to strip, clean and replace the fork seals but the caps were corroded severely, (check yours and if they're OK under the grommets pack them with grease to stop them corroding).
Hi. Thanks for the video. Any tips on how to slide the inlet onto the carb? I ran out out curse words while trying (and there are lots of curse words in Polish)...
Sadly no easy tips, just patience and plenty of curse words. It helps when the rubbers are flexible so if they've hardened a little they can be boiled in wintergreen oil to soften them.
@@spidiq8 Okay, thank you:) Today I'm also all out of patience so I will try again tomorrow.
@@ultorrotluultorrotlu That's good practice. Frustration rarely helps things fit. Another suggestion, if you have a hair dryer is to warm the rubber with that just prior to fitting it and a long thin blunt screwdriver can help hooking the lip over. Good luck with it tomorrow.
@@spidiq8 I'll give it a go. If I don't succeed I'll try drinking a beer before the next attempt;)
@@ultorrotluultorrotlu Followed by a big hammer and shouty swear words. 😁
Nice trick..
Hi, I do not know how I can solve the sulfur, and how is the cleaning. Is there a video, but a sequence from the first method to the end? Thank you.
I'm not sure what you mean, could you provide more detail please re the sulfur?
@@spidiq8 Yes, thank you, I do not have any idea about cleaning the sulfur, can I open the sulfur and clean it, and do you have WhatsApp communication?
@@wo.u I don't know what you're referring to by the sulfur, do you mean a part on the carburettor or another part of the fuel system. I'm happy to help but need to know what I'm helping with. No WhatsApp for my channel, sorry.
@@spidiq8 You have contact, such as Facebook or Instagram
@@wo.u There's my Facebook page but I don't check that as frequently as here.
m.facebook.com/profile.php?id=234082000050514&ref=content_filter
What you've done here is exactly what I've done minus the string
Hello, thanks for this video, i am italian, pardon for my writer, I tried this Bat I do not succeded, 2 hours, tried, tried, now I am tired, I go to bed. Tomorrow I Will try another 2 hours.thanks of all comment
Hopefully tomorrow will go better for you. They can be a real pain. To make them a little more flexible you can try putting them in boiling water for a few minutes.
Your English is excellent by the way.
Maybe if you snipe the twine instead of rotating it would be faster
Yes it would I imagine.
Still a struggle man,
Yep, they're always going to be awkward but all you'do is try to make it a little easier.
First put the rubbers in place and then the carbs.
Good luck with that. ;)
@@spidiq8 It's not easy but I did that way in my virago.
Hell this is the worst inlet rubber ever ........ 😑
They are probably the most awkward I've ever dealt with.
@@spidiq8 after two days of struggling just got it done :) thanx to the video it works .