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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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