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Join Date: Nov 2007
Location: Chandler, Arizona
You went BACK to the stock airboxes and exhaust? I have to wonder why. I've never heard of anyone else doing that before. I love the stock intake and exhaust, and have kept it on all my Vulcan 750s. Removing and reinstalling the carburetors is not easy compared to most bikes, but there are exceptions. The carbs on the first gen Honda Shadow VLX600 and the original Suzuki Intruder 800 are just as hard if not harder to work on. I have found a couple of ways that make getting the Vulcan 750 carbs on and off a bit easier. One is to trim some excess rubber off the airbox end of the ducts that go from the airbox to the carbs, which makes them more flexible and easier to get into place. Another is to use zip ties to hold the airbox (surge tank) right up against the top frame tube, to allow more working room and to prevent it from falling down in the way. Yes, this does require removing some other parts, but that is not really hard to do. A 1/4" wooden dowel rod with the sharp edges sanded down can help seat the upper end of the ducts in the surge tank (do not use a screwdriver, it will poke a hole in the duct) Soaking everything in WD-40 to make it slippery makes an amazing difference. I just used WD-40 to mount a new 150/90-15 rear tire, and it popped right on. If it is cold, a blow dryer will help soften the rubber. Don't use a heat gun, it will melt everything. But perhaps the best thing is to take your time and not get frustrated. It really isn't as hard as it seems when you are doing it for the first time. I got the whole engine out and back in without having to fight with anything, everything fit perfectly. But to do that I did have to practically disassemble the rest of the bike to get everything out of the way to avoid having to work around it.
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