installing carbs - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Carbs and Fuel System
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post #1 of 16 (permalink) Old 05-02-2009, 08:05 PM Thread Starter
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installing carbs

Hi All,
I pulled my motor to replace balancer dampers and just reinstalled the motor. I tried for 2 hours but can't get the carbs to go onto the intakes. PLEASE PLEASE HELP ME. Sorry, just venting some frustration. Anyway, any suggestions for making this easier will be greately appreciated. Also, I left the throttle cables install because I figured this would make it easier to reinstall the carbs.
Thanks,
Rick
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post #2 of 16 (permalink) Old 05-02-2009, 08:39 PM
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When you pulled the carbs, did you keep the front boot on the engine block, and the rear boot on the carb? That's the suggestion Clymer's offers and it actually works pretty well. So the first thing is to make sure the boots are where Clymer's suggests. After that's correct, one way to get the carbs to slip into the area is to crank the throttle cable and pull the connecting plate *up* - you can cinch down the throttle with a bungee or something. That also will give you more room. Third, the airbox (if you still have it) can impede putting the carbs on - try to lift up on the airbox as you move the carbs in between the cylinder head. Finally, bring the carbs in from the RIGHT side of the bike (as you're sitting on it). Oh, really, finally, finally - when you've got the carbs partway in, start to thread your choke cable through. It'll save you a lot of swearing when all's said and done. Good luck - and if you need more help, just shout out!!

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post #3 of 16 (permalink) Old 05-02-2009, 08:47 PM
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I just pulled mine for a cleaning and jetting. Coming off wasn't too bad, I thought it was going to be much more difficult. Going back on will be tricky. Now where is that bigger hammer?

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post #4 of 16 (permalink) Old 05-02-2009, 09:30 PM Thread Starter
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Hi,
thanks for thr reply. The boots are where Clymer suggests and the carbs are in position, I just can't get the carbs to slip onto the boots.
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post #5 of 16 (permalink) Old 05-02-2009, 09:44 PM
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Cuss words help.
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post #6 of 16 (permalink) Old 05-02-2009, 09:55 PM
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Take a little vaseline on your finger and run it around the inside lip of the boot. Or spray them with Armor All & wipe the excess. It leaves it slick.

Quote:
Originally Posted by rhlee View Post
Hi,
thanks for thr reply. The boots are where Clymer suggests and the carbs are in position, I just can't get the carbs to slip onto the boots.

JaY



"Veronica"
2002 VN750 Vulcan
Rebuilt Engine
ACCTs lubed w/TOC Springs
Pick-up Coils Gapped at .018"
Splines Lubed
Deka MF AGM EXT15L Battery
NGK Iridium IX Spark Plugs
R/R Relocation Fix
New Rear Rack
Stock Seat Repadded
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post #7 of 16 (permalink) Old 05-02-2009, 11:19 PM
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Quote:
Originally Posted by rhlee View Post
Hi,
thanks for thr reply. The boots are where Clymer suggests and the carbs are in position, I just can't get the carbs to slip onto the boots.
check to make sure the boots are rotated on the heads correctly,they are not straight but angled and make sure your clamps arefacing a direction that you can get to the screws,and the clamps have to be loose enough to allow the carbs to slip into the boots,I know this sounds silly but they can be tighter on the rubber boot than you think they are and not allow it to stretch over your carbs.If you have had both boots off completely you may need to leave them loose on the cylinder head so you can rotate them into the proper angles for your carbs,I hope this is a little help to you,they can be frustrating with the surge tank still on the bike, another good reason to do an earshave,it is an ease of maintenance issue LOL




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post #8 of 16 (permalink) Old 05-02-2009, 11:41 PM
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when min popped off after my engine rebuild.... i used a pry bar to reseat them... (be carful with this brute method but saves the ole muscles...



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post #9 of 16 (permalink) Old 05-03-2009, 03:32 AM
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Quote:
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Cuss words help.
and after pulling and replacing mine several times I came up with a few choice ones, so if you run out let me know I'll help you with some!

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post #10 of 16 (permalink) Old 05-03-2009, 11:53 AM
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Talked to and old mechanic and he said that the rubber boots gets stiff/hard and is not as pliable as new ones are. So he said get a pot of boiling water (sitting OFF the stove) and drop the rubbers into it. Let them sit in it about 5-10 min.
They should be very soft and stay that way long enough to get eveything back on.

I wonder if a hair dryer would warm them up enough to soften them when you get ready to take the carbs off.

JaY



"Veronica"
2002 VN750 Vulcan
Rebuilt Engine
ACCTs lubed w/TOC Springs
Pick-up Coils Gapped at .018"
Splines Lubed
Deka MF AGM EXT15L Battery
NGK Iridium IX Spark Plugs
R/R Relocation Fix
New Rear Rack
Stock Seat Repadded
Ext-BackRest
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