Need help with my 03 TLD Pred. carb reinstall:

So, I am installing my carb after installing my header pipe, rejetting, and drilling out the brass anti-tamper plug that covers the air mixture screw. It was supposed to be at 2 1/2 turns out from the factory, but it was over three turns out (from vibration?). I have set it at three turns for now and will try it at that setting. Of course, now it is easy to adjust.

Here's my problem: I cannot get the air intake black rubber boot to fit back over the rear carb throat. The black rubber part has a center ridge that I know must go over the metallic throat, then screw the hose clamp down tight. BUT, I cannot get that ridge to slip over the metal of the carb throat! Too tight. Just can't get enough muscle to the job, I guess. I tried putting a little filter grease on it so it would slide easier, but still no luck.

Has anyone had this problem? Any suggestions?

 

I have never heard of this problem before. Try using some wd-40 and see if that helps.

 

Am I correct that the inside ridge must go over the throat, then tighten the clamp down???

Otherwise, I'm afraid this intake will eventually slip off..... which it did the last time I had it off because I did not get the inside ridge over the throat when I put the air intake back on.

 

if its to tight, use lube...

that saying is pretty universal...


like he said.. wd-40... something flammable so when it gets into the intake it will be ok.

 

Another thing you can do is, since it is warm out now let the sun soften up the boot. Or you can just use a hairdryer to get the boot to soften up a bit more.

--DaveSP

 

Well, I called a Polaris mechanic I know and he said the inside ridge does not go up over the throat, it just butts up against it. This leaves only about 3/8 inch overlap for the hose clamp to work against. So, he said I should clean the filter grease off, slide it on the 3/8 inch, just butt it up to the ridge, and clamp it.
So this I can do easily....Sure hope he is right....I will be keeping a close eye on this joint.

 

Well, I got the thing back together and it seems pretty secure. I will just keep a close eye on it. Still seems to me that inside center ridge ought to be under the clamp.
Started fine and idles fine, engine accelerates fine....I can't wait to get it out on the beach and see how it performs.

My thanks to all of you who advised.