How do I remove the carbs to work on them?

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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.

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  • 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.