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Join Date: Nov 2007
Location: Chandler, Arizona
Without the airbox it will be easy. I just removed mine, and put them back WITH the airbox, and it was no fun at all. I had already removed the CA evap system and the air injection system, so those were out of the way. I removed both "ducts" that go between the carbs and airbox first, and put them back last. With lots of WD40, it's not that hard, they are so squishable you can just wad them up to get them into place. You need a Maglite, or some other small but bright flashlight to make sure they are properly seated in the airbox. DO NOT use a screwdriver. I poked a hole in one of the ducts that way once. But you don't have to worry about putting those back on. But you may have to remove and reinstall the carbs again. I removed mine with the throttle cables still attached, and put them back that way. It is virtually impossible to install the throttle cables with the carbs installed. The choke cable is not that difficult.
IMO, this is one of the worst designed setups I've ever seen, even removing/reinstalling the carbs on a Suzuki Intruder 800 is easy by comparison. But with plenty of time and patience, the right "feel", and doing everything in the proper order, it is not as bad as it first looks. I have fairly large hands, but after having been a mechanic all my life, I am good at manipulating parts in tight spaces. If you are "fighting" with it, give it up, go do something else, change your attitude, and come back. They do fit, it's just that everything has to be in exactly the right position, as there is no room left over anywhere. Jerry.
I am a motorcyclist, NOT a biker.
1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike