Carb Installation Tool

[Hepcat]

Hey all,

I would venture to guess that I'm not the only one who has trouble installing the carbs...having read about the "carb shimmy" in an earlier post, I thought I'd mention my 'secret weapon' for carb installation. Since I have the original airbox on one of my bikes, it's a real pain to put the carbs back in. I use a "Cotter Pin Extractor" to guide the rubber back over the carbs. It works really well. It now takes me about 5 mins to reinstall carbs vs. the 20 mins it used to take. Best of all, I don't need WD-40 anymore! The hardest part now is getting them lined up into position. After that, it's easy sailing.

The extractors I've seen are basically a dull awl with a couple of funky kinks in them. They have a 90 degree kink at the end and another smaller kink between the 90 and the handle. You may have one already and just never known what they were for. They're often sold in a package with other screwdrivers. They do sell them individually at Sears though.

If you're having trouble putting carbs back in, get yourself one of these things. You still have to muscle the carbs past the airbox and rubber boots, but it's easier when you know you won't have to fight the "carb shimmy" when you're done.

[Pat Kelly]

I've never had a problem getting my carbs on or off. I have the stock airbox. Om the triple site they made it sound even worse. Casrbs on wifes XS750F were just as easy. Put a chrome air filter (replaces the stock box) and it's even easier, I guess like pod filters. Still the stock box has never been a problem.
Hardest part for me is attaching the throttle cable. Needle-nose pliers work the best.

[John]

Try attaching the cable when you have the carbs half way in, and the linkage is easy to reach. That is if you put them in from the left side. Very easy.

[skids]

I feel like kicking myself in the ass every time I forget that step! You know what is worse...I did a complete install and then noticed that the diaphragm springs were still on the bench! OK, that only happened once.

Originally posted by John
Try attaching the cable when you have the carbs half way in, and the linkage is easy to reach. That is if you put them in from the left side. Very easy.

[macnut xj]

Pat, try it on an XJ sometime and you'll see what we're talking about! They use a whole different airbox system than the XS, and it gives you much less room to work. And with the XS you can do the "remove the bottom of the box" trick to gain room. Not possible on the XJ. There's just no easy way to do it. Yes, the hooked tool that Jon mentions does make it easier to get the boots back on the intakes of the carbs( I did that last time), but it's still a PITA to get 'em in and out.