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Getting to the Carb... (Read 3 times)
Probert31
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Getting to the Carb...
08/21/06 at 12:28:51
 
OK.  So I've read all the "white spacer mods.." and "carb" post I could find.  So far I've attempted to rejet twice.  The first time I took off the tank and tried to get at the top of the carb only to find that it was situated in such a fashion the screws were hidden under the frame.  That's when my son "hid" some bolts in the air filter.  I decided to stop at that point.  Feeling rejuvenated I went at it a second time.  I read the post about rotating the carb and really thought this was going to be it.  After disconnecting the hoses and loosening the carb, I found that it didn't clear the battery box, only about an 1/8 of an inch clearance.  It also would get hung up on the clutch cable (?) which I didn't want to remove.  So I took out the battery but couldn't see how to get the entire box out (it was getting dark...) thinking I could remove the carb altogether.  I guess my question is, are there any easier ways to get at the carb for rejetting?  I really want to do this myself, but the limitted space has me stymied.  If I do take out the entire carb, has any ever removed the throttle cable and have some thoughts on that process?  The whole thing has me a little squemish, seeing as I know I'm going to have to get in there again to properly tune the system.  Anyway, any advice would be greatly appreciated!!

PS.  I really don't trust my dealership to do the work seeing as my bike just returned from the 2500 mile check up with a mysterious oil leak.  I have also called some other dealerships who seem to feel I should just buy a Dynojet kit built specifically for the new muffler they want to sell me and have them install the whole thing.  Thanks again!!
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vroom1776
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Re: Getting to the Carb...
Reply #1 - 08/21/06 at 12:34:51
 
My first time, I did in fact yank the bat box.  Yep.  Don't buy the dyno jet kit, just buy mikuni jets from the stealer for a couple $ each.  

if I recall, you need to disconnect the throttle cable holder, then removing the throttle cable is easy.  As I recall, there are two ways to remove that guy.  1 is easy, 1 is difficult.  if the screws to take that off are hrad to get at, keep looking around that arae until you see ones that come off easier.

Or was it, jsut twist the darn thing and pull the cable out?

Ehg, that's kinda useless.
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ohms
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Re: Getting to the Carb...
Reply #2 - 08/21/06 at 13:02:28
 
If you dont plan on cleaning the carb you dont need to take it off. You can take off the float bowl screws and remove the bowl. It has gas in it so you have to be careful. Dont do it when the engine is hot. Once thats off you have access to the main jet and pilot jet. When i rejetted mine i mustve pulled the bowl off 10 times. Too much of a hassle to pull the whole carb off to change the jets.
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Probert31
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Re: Getting to the Carb...
Reply #3 - 08/21/06 at 13:12:25
 
Thanks for the response.

vroom:  Yeah.  I found the throttle cable holder, it just looked a little scarry to get off.

ohms:  I wish it worked like that for me.  The bowl is smack dab against the battery box and there's no way to get a screwdriver in there.  A real pain.  

Just as an aside, if I do remaove the carb, is there any way to move it forward, creating the necessary space to work on the bowl without taking the carb off?
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SavageDude
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Re: Getting to the Carb...
Reply #4 - 08/21/06 at 16:58:33
 
I've been thinking about that too. My thought is to cut some part of the battery box that keep the carb bowl from dropping down to change the jet. I guess it will be my next mod when I have spare time Smiley
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2005 S40, debadged, Tkat FB, saddle bags, sissy bar, HD Sporter muff, Fly screen, white spacer mod, 150 main jet.....and sssslowly upgrading
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Dynobob
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Re: Getting to the Carb...
Reply #5 - 08/21/06 at 17:14:39
 
Strange. I rejetted my totally stock '03 without removing the carb. I did rotate the carb an inch or two without doing anything to the cables. I was able to get to all the top and bowl screws and even put pointy vice grips on a few.

I can forsee you having trouble with the little screws that you have to take out to remove the needle. You need a very good screwdriver that fits the slot tightly. A magnet will help getting them out and to put them back in, tape them to the screwdriver with a little electrical tape.

Put a towel over the abyss where the starter resides. All your screws will end up there  Wink
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Guido
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Re: Getting to the Carb...
Reply #6 - 08/21/06 at 17:16:20
 
When I did the spacer mod and rejetted mine, I did not remove the carb or the bat box. Just the seat and tank.  I simply loosened the clamps holding the air ducts. That enabled me to wiggle the carb enough to get at the top screws, which were very tight by the way, actually had to use an easy out to get one out because the head stripped. For the ones on the bowl I used a right angle screwdriver. Those were not as tight. Then using a stubby screwdriver and laying down next to the bike, I changed the jets. Had to wiggle the carb and push rearward on the bat box  to get the bowl off too. But it will come off. Replaced the screws with SS allen heads I got from ACE Hardware. Whole project time about an hour more or less.
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Brewbrother
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Re: Getting to the Carb...
Reply #7 - 08/21/06 at 18:09:00
 
Its all here. The intake, carb and exhaust need an upgrade. Do them at the same time. Need any help? i've got time for at least 12 weeks.
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No spacer,60 pilot jet, 155 main jet, plug door, sportster muffler, k&n drop in, iridium plug, brake pedal mod,de-badged, Dunlops, bullet turn signals.
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Probert31
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Re: Getting to the Carb...
Reply #8 - 08/21/06 at 19:52:08
 
I'm sure I'll need help!  I'm going to try and remove the carb this weekend.  Sounds good in theory, but it took me 5 hours to replace my screen door.  Of course my brother helped, by bring over a 1/4 of Victory Whirlwind, but that's another story.  Thanks again for the advice and wisdom.  I'll let you know how it goes.  Probably by begging for more advice...
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