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Suzuki Across Carb Fitting

Discussion in 'Suzuki 250cc In-line 4's' started by px400, Dec 15, 2015.

  1. px400

    px400 Active Member

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    Hey guys, I may need your help!

    I use to ride a suzuki across until the day she decide to be naughty!
    Feel weeks ago I manage to work again on the bike, doing a big clean up on the carbs, replacing stuck cables and all TLC necessary.

    But now I've got problems to fit the carburettor on the manifolds. I'm not sure what is the trick to place, but seems to be in the wrong angle.

    Anyone here now any trick to install carbs and filter to match with the space under the boot?

    I upload feel pictures to illustrate the problem. That's a pain in the a*s right now.

    Thanks for any help.

    IMG_5230.JPG IMG_5229.JPG IMG_5231.JPG IMG_5232.JPG IMG_5234.JPG
     
    Last edited by a moderator: Dec 16, 2015
  2. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    They would go in a lot easier if you undo the clamps and use some rubber grease around the openings.
     
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  3. kiffsta

    kiffsta Senior Member

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    The way I do it is to remove the airbox first, then undo the 2 clamps on the carb holders so they are nice and loose, I then place the carbs against the against the carb boots with them slightly angled down, and lever them into the boot using a long piece of wood as leverage. ( I slide the piece of wood down into the frame, you will see a round piece of the frame that you can place the wood against to lever the carbs into position)

    Once they slide into the boot, do both screws on the clamp up. As for the airbox, loosen the bolts on the rubber clamps that attach to the carb, remove the 4 screws on top of the airbox and remove the top plate and filter. Then with one hand inside the airbox, massage the airbox boots onto the carbs and do up the 2 screws that hold the boot in place, reinstall the filter and top plate and do up the 2 x 10mm bolts that hold the airbox to the frame.

    Use some WD40 or similar lubricant on the carb boots and airbox boots to help the carbs and airbox slide into position.
     
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  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  5. px400

    px400 Active Member

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    I wasn't sure about that! Thanks god I didn't try to heat the rubber with fire!
    I will buy this grease and give another try!

    Thank you very much gentlemen s!
     
  6. Joker

    Joker See "about me" for contact details. Contributing Member

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    Loosen the clamps first bro, try that then go spending :)
     
  7. px400

    px400 Active Member

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    I already try it but since the rubber was to hard to move and I didnt have any idea of the rubber grease product I thought would be best to ask the masters here instead of try something else.

    Thanks for all help!
     
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  8. jnz92

    jnz92 Active Member Premium Member Contributing Member

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    Silicone works well. Convenient in a rattle can too.

    If the plasticizer has all flashed off, and the rubber has gone hard, try Rubber Renue, or one of the various homebrew solutions.
     
  9. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Gentle heat with a hot air gun (man's hair dryer) will soften them too.
     
  10. Pygmygod

    Pygmygod Well-Known Member

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    I had to cut a length of pine decking board the same width as the carbs and the board sits on the frame.

    I then line up the carbs onto the manifold boot things and put the board on the airbox side (airbox is removed) then whack the crapper out of it with a hammer until the carb round things slot into the manifold boot bits.
     
  11. px400

    px400 Active Member

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    Good Idea! Thanks for the advice.
    I managed to fit the carb almost perfectly, enough to allow me to start the bike in the first go! Yeaaaaaaaaaaaaaaaaaaaaa!

    Now I will just wait this crap weather in Sydney to stop rain and will finish to place all the bits in the right place and atempt to give another try with the bike completed assembled.


    Thanks for all help guys!
     
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  12. Phil

    Phil Senior Member Contributing Member

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