Gpz 600 airbox fitting

[cricklewood4]

Please somebody help I'm going round the bend trying to re fit the airbox on my gpz 600 I've tried softening the rubbers in a hot water bath but still can't get them to stay on the carbs I took the front off the airbox to get more access and I can just about get them on but as soon as I refit the rest of the airbox they slip back off the carbs somebody help please I'm getting rather frustrated

[_mjs_]

It was a pain in the arse doing it on my ZZR after changing the plugs. In the end I lubed up the rubber pipes with soap and took a gentle grip of them with needle nose pliers.

Perseverence is the main thing.

P.S wrong section, bro.
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Previous Bikes: 2006 Honda XR125L > 2003 Yamaha DT125R > 1996 Honda CB500
Current bikes: 1997 Kawasaki ZZR 600 E5 > 2006 Honda Varadero XL125V

[69chris]

i get them roughly in place and then use a hot air gun to soften them,
do one at a time, get it into place then clamp them on with the clip and move on to the next one,

pain in the arse i know and it makes you (almost) go out and buy some nice, new, supple ones........until you check out the price

patience patience patience

[andym]

If it's anything like the 750, I spent 2 days of creative language, blood, sweat and tears (ok I was trying to get the carbs between the engine and airbox because of the frame shape wouldn't allow it any other way), in the end I went for the heat gun, brute force and ignorance..... which done the trick in a few minutes

[cricklewood4]

Thanks very much for the tips guys got the airbox on after much moaning and threats to give up and scrap the thing.
I separated the front of the airbox so I could get my hands inside the rubbers to push them onto the carb inlets.
I used a batch of boiling water to soften up the rubbers.
Worked from left to right pushing one on at a time,used a hair dryer to soften the right hand side rubber until I finally got them in place
Refit the rest of the airbox to keep the rubbers pushed forward onto the carbs.
Job done easy peaty not

Next problems I have is with the indicator relay mine hasn't got one just a lot of cut wires
Bought a new one of the bay but the one I ordered only has two connecting tabs
Looking at the haynes manual there are three wires to connect to it an orange,a brown and a black and yellow so how does that work any ideas welcome most of the ones advertised on the net only have two connectors.

Third problem is a weird one on my cooling system the u shaped pipe on top of the engine has a small connector pipe coming out of it at the moment this is piped to the expansion tank in the belly pan is this correct please help this simple project is driving me mental