Carb manifold woes!

[buxtonmick]

Refitting the carb manifold is proving to be a right pain!  After 4 hours I've come to the conclusion that something must be amiss, so after checking the manifold stubs it looks like one of them is shorter than the others - is this right, and if so what cylinder should it be on?  As usual, the bits that should be straightforward are turning into the jobstoppers.  Aaaarghhh!!!!

[tom400f]

Hi Mick

Once again I will check tonight and post a picture. My carbs are just loosely sitting in the stubs at the moment so its easy for me to have a look.

I assume you mean the carb-to-head rubbers. I think these have their corresponding cylinder number written on the top. While you are waiting may be check that. No idea if there are pattern ones of these but if there are and that's what you have then may be they did not bother with the numbering - just a thought.

Lastly, since you will be doing this as well, getting the airbox in and connecting the big oval thing to the filter box is challenging. The way I did it was to fit the airbox first and tighten it to the carbs. With the filter connection not in the way at this point that's not too difficult.

Having suppled everything up by working in a bit of silicon grease (so both sides of the airbox and the large oval grommet that seals the flanged metal oval to the airbox) fit said metal piece into the grommet (thin rebate). Then offer this assembly into the filter box and into its orifice. You can get the thick rebate into the orifice at the top, then using a protected claw hammer you can lever the bottom into place (again picture coming).

[buxtonmick]

Thanks Tom, I've had the manifold in and out several times, just pushing the rubber connections past the filter box oval tube and the carb inlets.  I don't think it will be a pattern item as the bike was more or less original (and it has the dots on it, if that means anything!).  I'll take it off again later when I've calmed down and check for numbering.

Cheers, Mick.

[tom400f]

Oh - I think perhaps we are talking at cross purposes... you mean you are trying to refit the airbox (big oval on one side, carb connections on the other)...?

I never removed the carb stubs from that but as I said, it's out at the moment and mine is definitely original so I'll check it for you. No idea if that is numbered.

[tom400f]

View from above. Forget that cyl #1 looks a bit wonky - that's probably the jiggling to get it out. They all look the same to me and they appear not to have specific part numbers. I would say those bumps (on the stubs and the face of the airbox) should be lined up but mine seem to have assumed somewhat random orientations.

The carb-to-head rubbers are indeed numbered on the outside of the flat area that accommodates the uppermost fixing screw. They have separate part numbers for 1/4 and 2/3 so they are probably interchangeable in those groups

[tom400f]

Here's how I get that bloody connector in. Rubbers need to be soft, may be warm them. I lubed mine. Obviously not so much force as to deform the box.

[buxtonmick]

Thanks Tom, one of my connector rubbers is definitely shorter than the others and it's pretty stiff too.  I've tried it in a couple of positions now without success, even with heating them and lubing them.

[steven400/4]

the four rubbers on the chamber have nipples on themthey line up with four marks on the chamber so they line upto the carbs

[buxtonmick]

Thanks Steven, as I said, mines got those dots / nipples on but lining them up just doesn't help as the one connector appears to be shorter than the others - just wondering if they should be in a particular order?

Cheers, Mick.

[tom400f]

Can you post a few pictures of it?

[steven400/4]

1 and 4 are the same 2 and 3 are the same inlet rubbers are the same if they are not in the right place the chamber wont line up right not sure how to tell whitch is witch tho sorry

[steven400/4]

ir you need a hand i can come over i,m not far from you

[buxtonmick]

Thanks Steven - it's a fair trek from Burton!  I'll bear that offer in mind when things get really tough though.  Here's a couple of pics to try to indicate the problem, with the rubber on no 1 cylinder seeming to be slightly too short to reach when the others are in place., and as I say, it doesn't help that it is slightly harder rubber than the others.

[ST1100]

...it doesn't help that it is slightly harder rubber than the others.

Have you tried removing the air filter housing, reaching through the intake hose into the air box and pushing the front wall at #1 forward?

Had a very similar issue on a 650 and above method did the job.

[buxtonmick]

   Yep, but even when I get it more or less on it pops off again!  Definitely a problem with it so I'll see if I can get hold of another airbox - there's a couple on ebay at the moment (one looks a bit ropey though...)

Thanks, Mick.