This can be a frustrating process. The airbox and the carb boots in particular take some patience. Try to do it on a day when you aren't in a hurry.
You may want to consider doing the battery box mod first, to give yourself a little extra wiggle room.
First off, you need some tools
- #2 Phillips screwdriver
- Two 10mm wrenches
- Metric Allen key set
- 10mm socket, wrench, and 6 inch extension
- Two flat-bladed screwdrivers
Carb Removal Procedure
- Remove the seat.
- Remove both side panels.
- Remove the battery and the rubber battery boot (if applicable).
- Remove 2 10mm bolts that were uncovered when battery and boot were removed.
- Remove all the bolts holding the rear fender on. This and removing the battery will allow you to slide the airbox back and forth if you need the extra space.
- Disconnect fuel and vacuum lines from petcock.
- Remove all bolts holding fairing to gas tank. Keep careful track of where they belong.
- Remove gas tank to bracket bolts.
- Remove gas tank.
- Loosen all intake boot straps (between carbs and engine).
- Use screwdrivers to move airbox boot springs to rear slot.
- Push airbox back as far as it goes.
- Use screwdriver to remove the airbox intake boots from airbox, and remove them from the bike.
- Disconnect throttle cables: Leave the cables on the bracket and unscrew the single screw holding the bracket on. You won't have to re-adjust the cables AND it's faster.
- While rocking carbs up and down, pull carbs back and free them from engine intake boots.
- Use screwdriver at the top of the left intake boot and pop it free from engine.
- Remove carbs from left side of engine while disconnecting the choke cable.
- Carbs are now free of the bike.
- Plug the cylinders with a lint free cloth or paper towels.
Carb Installation Procedure
One tip: Re-installation works best if your carburetor boots are soft and pliable. If they are hard and stiff, try boiling them in water for an hour to soften them up. A couple, or up to 20, minutes in a warm clothes dryer has also been suggested.
- Remove other intake boot from engine using screwdriver.
- Install airbox boots back into airbox.
- Reconnect choke cable to carbs.
- Slide carbs fully into airbox boots; slide spring clamps into locking channel.
- Gently push carbs as far back into airbox as possible without shoving boots into airbox.
- Slide left engine intake boot between engine and left carb, and seat it into engine side.
- Slide right engine intake boot between engine and right carb, and seat it into engine side.
- Gently push airbox and carbs as unit into engine intake boots, and seat the carbs fully.
- Make sure carbs are still seated on both engine side and airbox side.
- Tighten engine intake boot clamps.
- Reinstall airbox bolts in battery tray area.
- Reconnect throttle cables, making sure throttle actuates properly.
- Reinstall gas tank, and reinstall all 6 bolts (4 allen on fairings, 2 for tank bracket).
- Reconnect fuel line to petcock.
- (optional) Connect vacuum pump to petcock and prime the carbs. Alternately, hook everything back up and crank the starter until the engine starts.
- Reinstall vacuum line from carb to petcock.
- Reinstall rubber battery boot and battery.
- Reinstall side plastics.
- Reinstall seat.
- Test ride bike and adjust idle speed.
If you have trouble figuring out where everything goes when it's time to put it back together, see Carburetor photos.
