carburetor install help.

barberman91 · July 30, 2016, 05:21:07 PM

I recently acquired a 1991 fj1200,, i just got the carbs back from being rebuilt. the bike came already with the airbox out. my question is, , what is the procedure for getting the carbs back connected to the airbox? I already got the airbox in place, is there any tips for getting the carbs back into the boots? I appreciate any help you can provide.

fjbiker84 · July 30, 2016, 06:56:19 PM

I recently had to pull my carburetors off to install a new cam chain adjuster. Getting them back on was a little more difficult than I expected so after fiddling around a few minutes I decided to coat the insides of each of the manifolds with engine oil. This helped a great deal and the final bit of seating was with a few gentle hits from a closed fist. My bike is a little different from yours in that (1) its an 84 and (2) the previous owner removed the stock air cleaner and put on individual K&N filters. So I can't imagine what the difficulty is in dealing with a stock air box - it's probably necessary to remove that, install the carbs, then reattach the air box. Hope this is of some help.

FJmonkey · July 30, 2016, 06:59:22 PM

I took my air box off because it was a pain to work on the carbs. Others say it is not so bad, I will let them offer up how they do it. The UNI pods sound better as well, at WOT you can hear the growl of the FJ beast.

Edit-
You can remove two bolts that hold the rear subframe and let it swing down and away. This will allow for more room to install the air box once the carbs are on.

barberman91 · July 30, 2016, 07:11:07 PM

I like the idea of the unipods, but will it affect the bike being that it is completely stock?

fjbiker84 · July 30, 2016, 07:38:06 PM

I think replacing the stock air cleaner with individual pods requires re-jetting the carburetors. The PO of my bike re-jetted the carbs after installing the pods (the stock setting in 84 was very lean to meet EPA emissions) but admitted to me that he ran into a bigger mechanical problem with the engine before being able to get it right. I later had a professional mechanic rebuild my carburetors and he said he had to order a different set of jets because the ones installed on my bike were too rich. I will be the first to admit that I know nothing about how to adjust/modify carburetors so I won't advise you on what to do. I will say that that I dig the cowl intake sound my bike makes - I've got the stock exhaust - don't wake up the neighbors in the morning as I head out on a ride. But giving my bike a fist full of throttle makes a howl that is intoxicating from the cockpit!

Tuneforkfreak · July 30, 2016, 08:50:27 PM

I say re jetting is a small price to pay in order to get that bulky air box outta the way. I think if I was forced to use that stock air box , I'd just get a different bike so I didn't have to ever see it again. I use petroleum jelly on my boots to help ease installation and it relaxes and conditions the rubber as well.

FJmonkey · July 30, 2016, 09:20:27 PM

I doubt a re-jet would be required if your exhaust was still stock. The exhaust is one of the two air restrictions so adding pods should be a simple bolt on.

fjbiker84 · July 30, 2016, 10:11:38 PM

Well, in that regard, if I had to bet, I would guess that my jetting was probably moved back close to the original factory settings. If I remember correctly, the original owner said the K&Ns came with a jet kit that was supposed to cure the problems caused by the EPA back in the day. Everything now is spot on except for what feels like a leaning out or hesitation at low RPMs - 2500-2800. That may be what the original owner was trying to fix. It's usually not a problem except when putting around in slow traffic.

a.graham52 · July 31, 2016, 01:38:34 AM

Heres what I do, iv learned a process so it's not too bad for me. Lube the air box rubbers real nice. And with the air box loose in the frame, slide the box and the rubbers forward onto the carbs. Seat the top of the rubbers over the carbs first. Then I reach though the air box with my hand and force the rubbers down under the carbs. Usually have to try each hand and various standing positions. This should get you quite far a long. Look under the rubeers and see if any are going INTO the carbs as apposed to around. Take a long flat headed screw driver and while apply constant forward pressure on the box, pick the remaining rubbers out. As u get more of them on the box will slide further ahead.

balky1 · July 31, 2016, 12:42:47 PM

AAAAnd don't forget to reconect crankcase breather hose after putting the air-box back in place.
If you think connecting air-box is a PIA, wait until you try this (unless you have small Japanese hands).

JPaganel · July 31, 2016, 01:21:42 PM

I have said it before, and I will say it again - the FJ is one of the easiest bikes to remove and reinstall carburetors, and airbox is not a problem at all.

I have no idea what kind of gymnastics you guys do to make it complicated.

balky1 · August 01, 2016, 01:37:34 AM

Quote from: JPaganel on July 31, 2016, 01:21:42 PM
I have said it before, and I will say it again - the FJ is one of the easiest bikes to remove and reinstall carburetors, and airbox is not a problem at all.

I have no idea what kind of gymnastics you guys do to make it complicated.

I agree. My GPz 550 was a PIA.

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carburetor install help.