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Old 02-11-2010, 09:59 PM   #11
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Installing those is pretty easy if you know the trick. First remove the airbox and install the seals into it. Now disassemble the airbox. Take the tray under the tool tray/ecu out by by spreading the box slightly to free the tabs. It just snaps in. Once that is out you will see the air horns. Remove the air horns the same way by flexing and unsnapping it from the box. Now reinstall the airbox and just reach inside the airbox with your hand to get the boots on the throttle bodies/carbs. Fasten the airbox in with its 2 top screws. Now just snap the air horns and tray back in and reinstall anything you had to remove to get it out. Done
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Old 02-11-2010, 10:04 PM   #12
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beautiful tip i will try that one tomorrow.
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Old 02-11-2010, 10:40 PM   #13
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you got it easy try the air box on the 00 and 01 440 SP's
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Old 02-12-2010, 12:31 PM   #14
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<div class='quotetop'>QUOTE (ACZR440's @ Feb 11 2010, 10:40 PM) <{POST_SNAPBACK}></div>
 Quote:
you got it easy try the air box on the 00 and 01 440 SP's[/b]
Better yet try a 87 Phazer or Exciter !!!
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Old 02-12-2010, 07:57 PM   #15
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Hey Ray,
I had the same problem with my 05 F7 carb, got to the point that I bought a new boot from Cat. When I compared both the old one was a 1/4 in smaller than new one. I dont know how the old one shrunk over the summer but it did, new one fit like a glove. Hope this helps
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Old 02-12-2010, 11:21 PM   #16
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im using some cracked ones i electrical taped from the junkyard.. makes them really not flexable, what would be the disavantages of removing airbox and putting 2 individual pvc pipe intakes on it so it gets air from up higher incase i fall into the river again?

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Old 09-26-2011, 03:59 PM   #17
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This forum is old, but I figured I'd try it

I have a 95 zrt 600, and I thought that's what I have to do, undo the airbox, then put em on. Well here goes
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Old 09-26-2011, 07:14 PM   #18
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 Quote: Originally Posted by UECAR View Post
<div class='quotetop'>QUOTE (ACZR440's @ Feb 11 2010, 10:40 PM) <{POST_SNAPBACK}></div>
Better yet try a 87 Phazer or Exciter !!!
better yet try a zrt 800
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Old 09-26-2011, 07:43 PM   #19
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 Quote: Originally Posted by leighthomas View Post
better yet try a zrt 800
I can imagine, I got it all together now, so now I can look at taking out the a arms, and painting them lime green!
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Old 09-26-2011, 08:07 PM   #20
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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.
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