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Removing
the airbox:
Now
that the tank is off the next step is to remove the stock
airbox and carburetor. First locate the clamp that
holds the airbox to the carburetor itself. Using
a flat blade screwdriver (a long one) loosen this clamp a
few turns (see picture 1). Now
locate the bolt at the rear top of the airbox. This
M6 bolt has an 8mm hex head. Remove this bolt and that
is all of the fasteners that hold the airbox to the carburetor
and to the chassis. Firmly grab the airbox and pull
straight up on it. This should allow it to separate
from the rest of the assembly.
Removing
the carburetor:
The
first step in removing the carburetor itself is to remove
the two bolts that hold the slide in place with a flat blade
screwdriver (see picture 2). This
is the point where the throttle cable goes into the carburetor. Once
the two screws are removed, the slide assembly will come
straight up and out of the stock carburetor. You can
now remove the cable from the slide assembly. Next,
loosen the clamp bolt that holds the carburetor onto the
manifold. Once this is loose, the carburetor and all
associated vent lines can be pulled out of the chassis. Next,
remove the fuel line from the stock carburetor. This
will be used on your aftermarket carburetor, or you can get
a new fuel line that incorporates a filter.
Removing
the throttle cable:
Now
is the time to remove the throttle cable from the splitter
junction. This is a simple process, but many people
get confused at this point. First remove the two M4
Allen bolts that hold the oil injection pump cover onto the
motor (see picture 3). Now
you will see where the second cable from the splitter junction
terminates. This is the oil injection pump cable. It
moves with the throttle cable to allow more oil into the
case when the throttle is opened. Carefully rotate
the arm that the cable terminates in to the rear of its travel
(see picture 4). You will
now be able to remove the cable end from the arm. The
junction splitter is made in two halves so you can remove
the cables from it. The top cap is pressed on pretty
well so some force will be required to break it loose. Once
loose, you simply push both cables and the piston upwards.
They ride in a small groove inside the junction. Remove the
throttle cable from the junction splitter. If you are
going to premix from now on, leave the oil pump cable disconnected. If
you are going to continue to run the oil injection system,
then take note of how the cables were routed and how the
ends fit in their respective places. When reinstalling the
cables, hook up the oil pump cable only after you are finished
reinstalling cables inside the splitter junction.
Removing
the manifold:
Removing
the manifold is accomplished by removing the four M6 Allen
bolts with a 5mm Allen driver and taking off the two small
hoses that serve to heat the stock manifold (see
picture 5). These hose clamps can be easily removed
with a set of wire dyke pliers, and then the hoses must be
pulled free. Take note at this point that two of these
bolts hold stuff in addition to the manifold. The one
in the top left of the manifold also holds three grounding
wires that must be reconnected in order for your bike to
run. The one in the bottom right holds the clutch cable
in place. Take a careful look to see how these are
installed. These both will need to be reinstalled on
your new manifold. Once the four bolts are removed,
the manifold should be free to come off. Sometimes
the gasket will cause it to stick and some tapping with a
rubber mallet may be needed.
Removing
the reed cage:
At this point, you
may either be replacing the entire reed cage, the reeds themselves
or just removing the restrictor. You
should see the backside of the reed cage at this point. It
has a small opening that matches with the exit of the manifold. To
remove the cage, try first to simply pull it out of the case
with finger pressure. If that fails, resort to careful
tapping and prying. This small opening is the reed
cage restrictor (see highlighted picture
6). It will only restrict your motor, if you are
running a carburetor larger than the stock 12mm. For
a stock carburetor, the restrictor is not a bad thing, since
it smoothes the transition of air into the reed cage. For
all the big carburetor users, it must come out.
The
easiest way to remove the restrictor is to first remove
the reeds and reed stoppers (be careful), and attack the
restrictor from the front side (see
picture 7). Hold
the cage firmly and use a sharp Phillips screwdriver bit
to remove the four screws that hold the reeds down. Once
these screws are out, carefully pull the reeds away from
the cage, and lay them down on a clean surface in the same
way they were positioned in the cage. This is important,
as reeds are usually curved to a very small extent to aid
in their sealing. They need to be fitted in the same
way they were originally fitted. With the reeds removed,
take a screwdriver of the appropriate size and push on the
restrictor from the back side. It will require some
force to make it come out. Be careful not to let the
tool push against anything but the restrictor (see
picture 7). You
do not want to damage the sealing surfaces of the reed cage.
Carefully reinstall the stock or carbon reeds and the reed
stoppers.
Proceed to Step
4: Removing the Stock Exhaust
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