Join Date: Jan 2010
Location: Buffalo, NY
Thanked 17 Times in 13 Posts
Sled: 2000 Arctic Cat ZR 600 EFI
10-11 Mileage: 900
09-10 Mileage: 250
08-09 Mileage: 500
The easiest way to do it, honestly, is to remove the airbox. I've done it about 6 times this summer to work on different things.
To install them, first, pull the top off of the airbox and remove the inside baffle, then, remove the airbox by pulling up and rotating the top towards the front of the sled. The whole airbox should lift out. Then, remove the carb assembly from the boots by pulling back on the carb assembly. Then you should be able to remove the carb boots from the crankcase and removing the oil injection tubes from the bottom.
Then change the carb boots and secure them to the crankcase. Next, reinstall the oil injection tubes to the bottom of the carb boots (the left one on the oil pump goes to the left cylinder). Once those are installed, you are ready to reinstall the carb assembly. Put the carb assembly back into the carb boots but do NOT tighten them back down. Now, reinstall the airbox by rotating the top of the airbox towards the back of the sled why pushing down. You may need to do this in a few steps, while you adjust the carb assembly up to snug it into the airbox. Once the airbox is seated, you will probably need to adjust the rubber surround on the airbox around the carb intakes. The top should be around the outside of the carb intake, but the sides and bottom may actually be folded / pinched on the inside of the carb intake.
What you can do easily is use a small screwdriver or something flat but rigid and put it between the rubber surround and the outside of the carb intake along the top. Slowly work your way around the side and the bottom, then the other side. Once that is done, the entire surround should be on the outside of the carb intake. Repeat for the other carb intake, and then you are done!
It seems like a lot of work, but it is worth it and it ensures that you will have done it the right way.