I recently completed the carburetor rebuilding, intake o-ring replacement, and bench synced the four carburetors so that they will be opening an equal amount when I attempt to start the bike for the first time. Now it it is time to start putting some parts back on the bike. Namely the clutch cable, air box, and carburetors.
First was the clutch cable while there was still plenty of room to work. The previous owner had already removed the clutch cable and had provided a cable in the parts box for the replacement. He had indicated that the cable was needing to be replaced due to stretching. When I routed the new cable and attempted to connect it to the clutch actuator arm, it wasn’t even close. I don’t believe the cable could have stretched that far. Here is a before photo on the left and the after photo on the right.
The position that the clutch actuator arm is in now is correct and is a much better alignment to achieve the most mechanical advantage with the cable pull being 90° to the arm.
Next it was time to start putting the air cleaner, air chamber, and carburetors back into the frame. It took some trial an error and I got a workout trying to get everything back together. Didn’t find any pictures of the before shot to show the relationship between these components and the frame. What I found to be the correct order to install these parts is a s follows:
- Install the air cleaner box into the rear of the frame through the middle of the frame without the cover on the box. Don’t screw it into the frame yet.
- Insert the air chamber into the air cleaner box. These two pieces will slide back and forth a bit to provide room to get the carburetors in, but movement is limited by the frame that is between these two components.
- Dielectric tune-up grease was added to the inside of the intake boots to help the insertion and improve the vacuum seal.
- Have all of your hoses for fuel, vacuum, and vent connected to the carburetors. No way you will get these in later.
- As you are sliding the carburetors in from the side of the bike, connect the choke and throttle cables to the front of the carburetor between carburetors no. 2 and 3.
- Squeeze the carburetors in between the boots from the air chamber and intake boots on the block.
- Once you are lined up between all of the boots, get the carburetors into the intake boots first. I needed a third hand helper of a strap clamp to keep things aligned and squeeze the carburetors into the boots. Tighten the intake boot clamps.
- Slide the air chamber boots onto the backs of the carburetors. Tighten the boot clamps.
- Screw in the air cleaner box and install the air filter and cover.
- Mount the regulator/rectifier to the bottom of the air cleaner box with ground wire to the battery box.
- Connect the breather hose between the air chamber and the cylinder head. I should have put the hose on the air chamber before installing the chamber into the frame. I couldn’t get the spring clip on after the fact and resorted to a traditional hose clamp instead.
- Route the two vent hoses to the rear of the bike in front of the rear wheel.
- The fuel and vacuum hoses will be completed when the fuel tank is reinstalled.
I think that was it. Pretty hot and tired after that effort.
Photo of everything going together with the strap clamp helping me out.
And then everything complete.
And maybe one more trying to clarify all of the different pieces that were crammed into a tight space.