Here are hints that worked for me:
Removal
- Put the bike on its center stand or a lift to be level.
- When removing the tank, remove the filter cup and PUSH the gas lines off the fittings with a screwdriver.
- Remember to disconnect the throttle cables. (Obviously, remove the air filter.)
- When removing the velocity stack housing, loosen the clamps until the ends are about to separate.
- The housing should come off fairly easily because this part of the carburetor is smooth.
- The carburetors will separate from the (black) manifolds, not the manifolds from the engine.
- Loosen the rear manifold clamps until the ends are about to separate.
- Move them up by the forward clamps.
- It can't hurt to try to get some penetrating oil at the rear of the manifolds.
- Heat the manifolds with a heat gun.
- Straddle the bike, grasp the carburetors and yank them vigorously up and down with a little tugging.
- No go? Use leverage; get a piece of wood .5"x1.5"x4". The thickness is roughly the maximum.
- On the right side use the wood to protect the fins, Any lever will do to push on the carburetor bar.
- On the left side the choke is in the way so use the indicated hole.
- Any lever that fits will do. If it's too difficult, get a longer lever.
Installation
- Put lube on the outside of the carburetor lips and the inside of the manifolds.
- Heat the manifolds with a heat gun.
- Get the carburetors inserted enough in the manifolds to stay there.
- Use leverage as in the photos. 2"x4" boards work well.
- Get one side at least 1/2 way in. Then get the other well in. Go forth as needed till they're home.
- Or use two levers and a friend.
I found this install method gave a really comfortable feeling of total control over the process.
