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XJ11 - how to best remove/replace carbs & airbox

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  • XJ11 - how to best remove/replace carbs & airbox

    I'm still dancing on the fence about carb mods and what to do at this point.

    My XJ11 came with a rusty MAC 4:1 and terribly malfunctioning carbs. The bike was seemingly running quite lean & was sucking gas like crazy. Because it's no longer stock and there is the 4-1 exhaust already on it and it's running lean, I've bought pods and a Dynojet kit for it which is supposed to work well with the 4-1 & pod configuration and give a fairly balanced non lean burn (at the expense of gas mileage).

    I had tried to remove the carbs the same way I do on my XJ650J but the intake boots on the XJ11 go very deeply into the airbox while on the XJ650 they only go 1/3" into the airbox and will pry out fairly easily. Getting the boots off the XJ11 carbs took a whole lot of prying to just get them off the carbs & they were stiff as could be. There was so little room to work with... I eventually was able to pry the boots off & was able to pull them out of the airbox so the carbs could come off the intake manifolds. I decided at that time I would be best go with pods if only to allow me to have access to the carbs when I needed to do so.

    I haven't moded the carbs yet and still have the airbox, snorkel & boots (can't undo the already existing 4-1 exhaust) but would be willing to at least see how it works with stock carbs that are rebuilt and properly synced . Problem is I can't see how you are supposed to remove or replace the carbs with the intake boots in place; reinserting those stiff boots into the airbox & then getting them on the carbs would require Houdini.

    I considered cutting the airbox in half and taping it together in hopes that might facilitate getting the boots on & off the carbs but decided it probably wouldn't help that much considering how the boots are so deeply sunk in the airbox.

    So... while I have time to play around, how do people best get those carbs on & off the stock XJ11 setup?

    Thanks
    82 XJ1100 Maxim "hurricane"- DEKA EXT18L AGM battery , NGK BPR6EIX spark plugs, Green Dyna coils, Sylvania SilverStar Ultra H4 bulb, 139 dB Stebel Nautilus air horn, Home-made K&N air filter based on an original paper filter frame, new piston rings, Barnett Clutch Springs, SS braid/Teflon brake lines, TKAT fork brace, rebuilt calipers, master cylinders, new brakes, reupholstered seat, lotsa little things and so many answered questions here.

  • #2
    I agree the XJ airbox is a booger on carb in and outs. Use a liberal dose of WD40 on/in the front and rear boots.use your finger or a small wipe to get it inside them all around. Probably help if its not too cold either . It certainly is a tough jam to get them in but they will go. Watch out for the throttle lever to not bend it.When they are basically in position, install in the front boots first, once seated there you can finagle the airbox boots on. Also Be sure the clamps are pushed back first

    If that XJ was the first I ever pulled it would seem next to impossible. But I was lucky to have a bit of practice on my SF so I had the concept down. It is a booger in comparison.

    I will add that I used pods on the XJ for initial fuel line set up and used the sky squint method for bench sync so it ran really good for some running test.
    Then I pulled it all off and reinstalled the airbox and gave it a good sync
    79SF
    XJ11
    78E

    Comment


    • #3
      Are you saying you first removed the intake manifolds to the head to get the carbs off?

      This one area of concern was less than well designed as regards repairs in the future.

      I really would prefer to keep it as close to stock as possible.
      82 XJ1100 Maxim "hurricane"- DEKA EXT18L AGM battery , NGK BPR6EIX spark plugs, Green Dyna coils, Sylvania SilverStar Ultra H4 bulb, 139 dB Stebel Nautilus air horn, Home-made K&N air filter based on an original paper filter frame, new piston rings, Barnett Clutch Springs, SS braid/Teflon brake lines, TKAT fork brace, rebuilt calipers, master cylinders, new brakes, reupholstered seat, lotsa little things and so many answered questions here.

      Comment


      • #4
        Practice, that's how you get it figured out. Never worked on an XJ so I can't say bit the first time I tried pulling the carbs on my E was not fun, probably took me 45 minutes to get them out, now I can pull them off in couple minutes. Most time consuming part is loosening the boot clamps.
        Nathan
        KD9ARL

        μολὼν λαβέ

        1978 XS1100E
        K&N Filter
        #45 pilot Jet, #137.5 Main Jet
        OEM Exhaust
        ATK Fork Brace
        LED Dash lights
        Ammeter, Oil Pressure, Oil Temp, and Volt Meters

        Green Monster Coils
        SS Brake Lines
        Vision 550 Auto Tensioner

        In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing.

        Theodore Roosevelt

        Comment


        • #5
          I know I'll get a bunch of grief but that's why I went to pods. Gives you loads of room in there.
          1995 KZ100P
          Pods, jets, pipes, cam adjuster, oil cooler

          1977 Ironhead - custom build
          Hot engine, custom frame, KZ front and rear, high torque starter, alternator conversion, Progressive shocks, Thunderheart wiring, Dyna ignition, oil cooler, Dakota Digital instruments, etc.

          Sold all my XS's to Eastcoaster but still love to keep up with you guys. This is the best cycle forum on the web.

          Comment


          • #6
            The boots on the airbox don't need to be removed to take the carbs out, cutting the airbox is also not necessary.. Unbolt the airbox and slide it back, it only moves back less than 1 inch. But it is enough to pull the carbs out. Put some silicone of other lube on the rubber boots it will make getting them out easier.
            With the airbox slid back push the rear of the carbs down to disconnect the throttle cable. Then pull the rear of the carbs up and push the front down and slide them out. Doing this will keep the throttle linkage from hanging on the intake boots.
            Slow down and enjoy life. If you are in that much of a hurry, you should have left eariler.
            Current rides:
            80 XS1100SG
            82 JX1100
            83 Venture Royale
            86 V-Max

            Comment


            • #7
              Read this carefully, do not remove the v bracket bolts

              http://www.xs11.com/xs11-info/tech-t...rburetors.html
              1978 XS1100E
              1982 XJ650RJ Seca
              2001 Yamaha XT225
              2002 Suzuki DR650
              2008 Suzuki DL650 VStrom
              AMA charter life member

              Comment


              • #8
                Originally posted by Tom Andersen View Post
                Read this carefully, do not remove the v bracket bolts

                http://www.xs11.com/xs11-info/tech-t...rburetors.html
                Unfortunately the XJ airbox lower cannot be removed on the bike . that's one reason the XJ is more of a pain. And the adapters seem to be a little stiffer. And the airbox doesn't slide rearward as much as an XS. I even tried to put an XS airbox in there. Dont fit
                79SF
                XJ11
                78E

                Comment


                • #9
                  I have not owned an XJ...yet. And I know several folks who ditch the factory air box on the XS to make carb work easier.

                  I know the XJ air box is even worse, so no one will hate or blame you for making the switch for that reason alone.
                  Life is what happens while your planning everything else!

                  When your work speaks for itself, don't interrupt.

                  81 XS1100 Special - Humpty Dumpty
                  80 XS1100 Special - Project Resurrection


                  Previously owned
                  93 GSX600F
                  80 XS1100 Special - Ruby
                  81 XS1100 Special
                  81 CB750 C
                  80 CB750 C
                  78 XS750

                  Comment


                  • #10
                    I've ordered some pods for this reason. We'll see how much of a pia it is to get the jetting right.
                    1981 Special- currently under construction

                    Comment


                    • #11
                      I personally would never choose playing around with jetting over fighting an airbox. If I had a messed up bike to start with maybe, but so far .......no. A messed up bike would be a parts bike.
                      79SF
                      XJ11
                      78E

                      Comment


                      • #12
                        It does take a little of Practice. It also reuired that you tounge stick out of your mouth to the side alittle while doing it, But the advice youv'e got hear is so far pretty good. I have two XJ1100s and here is what I have figured out.

                        You should never take the boot off the intake side. (They around gasketed and will leave like a sieve if your dont seal them up good. High temp RTV, and will make tuneing damn near impossible if they do leak)

                        A heat gun (or blow dryer) on each airbox side boot will help alot when takeing them off the bike. The other side is a different hard type of that will only burn not get softer with heat.

                        Take loose the air box bolt on the top to let your self have about 1/2 inch extra for room to play with.

                        First time you have the carbs off take the boots out of the air box, and use a dremel tool with a sanding drum, regular 80 grit sand paper, file, or what ever fancys you to try to ease open the size of the holes in that air box about 1/16 to 1/8 inch bigger.

                        Also while you are Cleaning working on your carbs, Soakk them in Armor-all or back to black to help soften them up (squeeze them and massage them occasionaly). I think some guys have boiled them vinger or something to soften them up, but I've never tried that so I dont know.

                        Next when putting them back on the bike, Soak the air box side in Hot water, or use the heat gun to make sure they are nice and soft.

                        Install them into you air box first in proper order (I know from experiance it dont work well other wise! )

                        Lube the inside of all the boots with a little silicone or motor oil.

                        Then slide them in from Starboard to port (right to left)

                        Worry first about getting them into the engine side boots first. Shoving them as deep as they will go, A block of wood or hammer handle work good for shoving them in their all the way.

                        Them work on poping you air box side around your carbs. More then likely they are all semi colapse about them selves in weird U's and such and this is were the tounge thing comes into play. Use you long phillips screw driver to help along the way pushing, poping, squeezing,and swearing it right. This is the practice part and gets easier the more you do it.

                        Seriously though once you know how to go about it. Takeing the Carbs on and off should be no more then a 5-10 min job each way.

                        Heck I think getting the gas tank back on with out pinching a fuel line off in the Octy is more time consumeing


                        Good luck!

                        Comment


                        • #13
                          Hi Camel,

                          Excellent! I'll do that. Don't want to take too much off the airbox but I do have a dremel & one of those sanding discs so it shouldn't be too big of a problem. I'll give your suggestion a go though. For the life of me I can't understand why Yamaha didn't either shorten the box by an inch or so or extend the airbox compartment backwards an inch or so, it would make working on the bike so much easier.

                          That was a really descriptive answer and I really appreciate it.

                          Cheers!
                          82 XJ1100 Maxim "hurricane"- DEKA EXT18L AGM battery , NGK BPR6EIX spark plugs, Green Dyna coils, Sylvania SilverStar Ultra H4 bulb, 139 dB Stebel Nautilus air horn, Home-made K&N air filter based on an original paper filter frame, new piston rings, Barnett Clutch Springs, SS braid/Teflon brake lines, TKAT fork brace, rebuilt calipers, master cylinders, new brakes, reupholstered seat, lotsa little things and so many answered questions here.

                          Comment


                          • #14
                            Originally posted by KA1J View Post
                            Hi Camel,

                            Excellent! I'll do that. Don't want to take too much off the airbox but I do have a dremel & one of those sanding discs so it shouldn't be too big of a problem. I'll give your suggestion a go though. For the life of me I can't understand why Yamaha didn't either shorten the box by an inch or so or extend the airbox compartment backwards an inch or so, it would make working on the bike so much easier.

                            That was a really descriptive answer and I really appreciate it.

                            Cheers!
                            just ease it open a hair (you dont wanna make a leak) The bike really does run at its best in the stock setup if you have the patience and smarts to learn it's quirks.

                            Comment


                            • #15
                              Originally posted by thecamelman79 View Post



                              First time you have the carbs off take the boots out of the air box, and use a dremel tool with a sanding drum, regular 80 grit sand paper, file, or what ever fancys you to try to ease open the size of the holes in that air box about 1/16 to 1/8 inch bigger.
                              Curious about the point of this
                              79SF
                              XJ11
                              78E

                              Comment

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