Cherrypicker
Member
I am working on well actually it is a Venture Xl early 90's vintage. These have the same engine and setup of the 480 Phazers.
I have pulled the carbs on many of these machines and they are in general difficult. I am wondering if there is anything that some of you do that might make this easier. I pop the little door on the fuel tank cover to expose the one or two bolts anchoring the air box, this gives minimal movement of the airbox. I pull the boost bottle, then remove the carb choke assembly with the choke lever activated to insure that the plunger/spring assembly doesn't come apart and fall in the engine bay. All hose clamps are loosened to the fullest extent, and the carbs are pulled back to come out of the intake manifolds, I work the carb rack CCW from the front so that the throttle cable and oil pump cable are more easily removed. Most of the gas lines in these older sleds are stiff and hard, so I used a "heat gun" hair blower to heat up the lines and soften then for removal from the carb spigots. I then wrestle the carb rack and boots until I can pull the assembly out. Frequently you might drop one of the air box clamps down in the engine bay, or distort them.
More recently in replacing the carb rack, I have moved the air box clamps all the way back over the carb throat and rolled the boot back so it is folder over the throat, this seems to give me a bit more clearance and install is by reversing the steps in removal. I have heated up the boots to make them a bit more pliable. Rolling the boots back onto the airbox so they properly fit is another time consuming process. While in there I'd recommend pulling the air box out to access the fuel pump and replacing the gas lines from pump to carb, maybe adding an inch or two in length, making it easier to reconnect the lines to the carbs.
I have pulled the carbs on many of these machines and they are in general difficult. I am wondering if there is anything that some of you do that might make this easier. I pop the little door on the fuel tank cover to expose the one or two bolts anchoring the air box, this gives minimal movement of the airbox. I pull the boost bottle, then remove the carb choke assembly with the choke lever activated to insure that the plunger/spring assembly doesn't come apart and fall in the engine bay. All hose clamps are loosened to the fullest extent, and the carbs are pulled back to come out of the intake manifolds, I work the carb rack CCW from the front so that the throttle cable and oil pump cable are more easily removed. Most of the gas lines in these older sleds are stiff and hard, so I used a "heat gun" hair blower to heat up the lines and soften then for removal from the carb spigots. I then wrestle the carb rack and boots until I can pull the assembly out. Frequently you might drop one of the air box clamps down in the engine bay, or distort them.
More recently in replacing the carb rack, I have moved the air box clamps all the way back over the carb throat and rolled the boot back so it is folder over the throat, this seems to give me a bit more clearance and install is by reversing the steps in removal. I have heated up the boots to make them a bit more pliable. Rolling the boots back onto the airbox so they properly fit is another time consuming process. While in there I'd recommend pulling the air box out to access the fuel pump and replacing the gas lines from pump to carb, maybe adding an inch or two in length, making it easier to reconnect the lines to the carbs.
I completely remove the clamps that tighten around the airbox side of the carburetor. I remove the plastic shrouding piece in front of where ones knee would be. Remove the intake piece over by the steering post for the airbox.
Remove airbox. Then remove anything else that attaches to carbs.
When re-installing, one of the last things I put on is the clamps around the airbox side of the carbs. Just feed them around and put the screws back in.
Remove airbox. Then remove anything else that attaches to carbs.
When re-installing, one of the last things I put on is the clamps around the airbox side of the carbs. Just feed them around and put the screws back in.