Kawasaki Motorcycle Forums - View Single Post - KZ550 Airbox install (with engine installed!)

vinnye · 08-08-2008

You should be fine.

I have done Z750 and ZL1000 airbox and carb reoval and installation - but not a 55o. But dont think there will be any major differences in method.
If you can find some new intake rubbers that will definitely help. If the old ones are hardened - it will be a LOT HARDER.!
I would suggest, since you have the carbs off, manouvre the airbox into the space, but do not fasten the bolts up. Allow the airbox to sit in place but with the bolts loose, you should be able to wiggle a bit more room!
Attach the intake rubbers to the airbox (be careful, they are usually in 2 pairs, for the different carbs!). Some people fold the intake rubbers back and hold them in that position with a Tie wrap or Jubilee Clip etc.
Also. a thin piece of plastic can be used to help slide the carb rack past the inlet manifold stubs.
Line the carbs up with the inlet stubs, and by pushing the carb rack down and then in, slide them onto the stubs. (A little engins oil on the rubbers may help here!). Be careful these stubs can be damaged fairly easily!
When the rack is in - do not fasten the clips yet.
If you tied the intake rubbers up, loosen the middles two and flip them over the carbs. The do the outer two.
Now you can button everything up

I used a tool like this, to aid in flipping the rubberss. It is made from a briclayers metal tie - with one end straightenewd and trimmed off.

08-08-2008	#5 (permalink)
vinnye Finally Got Into First Gear BTK Beginner Join Date: Mar 2008 Posts: 72	You should be fine. I have done Z750 and ZL1000 airbox and carb reoval and installation - but not a 55o. But dont think there will be any major differences in method. If you can find some new intake rubbers that will definitely help. If the old ones are hardened - it will be a LOT HARDER.! I would suggest, since you have the carbs off, manouvre the airbox into the space, but do not fasten the bolts up. Allow the airbox to sit in place but with the bolts loose, you should be able to wiggle a bit more room! Attach the intake rubbers to the airbox (be careful, they are usually in 2 pairs, for the different carbs!). Some people fold the intake rubbers back and hold them in that position with a Tie wrap or Jubilee Clip etc. Also. a thin piece of plastic can be used to help slide the carb rack past the inlet manifold stubs. Line the carbs up with the inlet stubs, and by pushing the carb rack down and then in, slide them onto the stubs. (A little engins oil on the rubbers may help here!). Be careful these stubs can be damaged fairly easily! When the rack is in - do not fasten the clips yet. If you tied the intake rubbers up, loosen the middles two and flip them over the carbs. The do the outer two. Now you can button everything up I used a tool like this, to aid in flipping the rubberss. It is made from a briclayers metal tie - with one end straightenewd and trimmed off.