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Removing the Carbs from the RSV


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How to remove the carburetors from the '99 to present Royal Star Venture

 

Thanks to Cougar for this excellent article.

 

This was my first time removing the carb cluster from my 2000 RSV. This project took me about 30 to 40 minutes to do including the seat and tank removal. I think it is a pretty easy job to tackle.

I tried to take as many pictures as I could. In the write up I used only 2 instead of 5. You will get the idea.

 

1. Remove the seat and fuel tank.

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2. Now you will see the cable and cord clamps. Remove all the screws shown below.

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image006.jpg.0dfcb74e2bcb52502aaf60c4d526ac5d.jpg

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3. No need to remove these screws.

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4. Remove this hose from the right surge tank.

image016.jpg.4e4bb1ac4bc6abf0af294779bc6a00a7.jpg

 

5. Now loosen the clamps on the front of the surge tanks (2) as shown below.

image018.jpg.bfa3c9065bfce652cfef7722309839ec.jpg

 

6. Now loosen all four clamps on the bottom of the surge tanks that are attached to the top of the carbs in four places, one on each carb.

image020.jpg.018c678190aa5dfdcb273401b645a431.jpg

 

image022.jpg.81357046d863725d331c4e8cbf1a97c1.jpg

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7. These wires and hose will go towards the middle.

image034.jpg.c4b342dd4281061e68d603b166a3ebf0.jpg

 

8. Pull the left and right wires and hoses to one side of the surge tanks. Do not worry, they will stretch far enough.

image028.jpg.a6103bdbe1f1b6e5303a639b1b4a8b5b.jpg

 

image030.jpg.f070859dfbdc3db754f623d3e7579bbf.jpg

 

image032.jpg.6fd346b1164acf1f55c73a659294c40d.jpg

 

image034.jpg.c4b342dd4281061e68d603b166a3ebf0.jpg

 

9. Now remove the tank surge union.

image036.jpg.cbd5e80f34e4c1409fa721dd299b4ec9.jpg

 

10. Now start wiggling and pulling up on each surge tank.

image038.jpg.788ab0f49f5b0af88c1bee71423eef68.jpg

 

image040.jpg.0e07510644cb78ebb4b0d4e5e5eae530.jpg

 

image042.jpg.203e8022a71f91936ad9eac7e4a40415.jpg

 

11. Remove one vent hose on each surge tank and then they will be free and out of the way.

image044.jpg.e48cc7272000defe979acab1e20eb04d.jpg

 

image046.jpg.218c5bef6e932944bf056b2e147cefba.jpg

 

12. Remove both left and right overflow hoses from each carb.

image048.jpg.3919f4c633919e3a177d251e6c3017d6.jpg

 

image050.jpg.4fccb7ef64b1ddc631da36434aaae3f0.jpg

 

image052.jpg.58d7c0f26c0c2d2319a7f43242999733.jpg

 

image054.jpg.5fd71ab0be5d6616d8180c9f831253ca.jpg

 

13. Next, split apart the two wire connectors on the left side front of the carbs. I think that they are heater and sensor wires. I always have hated the black connectors.

image056.jpg.894195db58ca66f4e438e5989544f1d2.jpg

 

image058.jpg.b8094b512b0377614cc4ca613a8c208b.jpg

 

image060.jpg.8d3770c7f27184ebc7a262ae66de7abd.jpg

 

image062.jpg.40c8d68a3754185e55fd1bf924123758.jpg

 

14. Now the fun part. Loosen both nuts on the throttle cable housing. (NOTE: REMEMBER AND MARK THE TOP AND BOTTOM) in the pictures I just remembered that the top nut and lower nut are different.

image072.jpg.1e170e2c900aad7843d996051639927b.jpg

 

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image066.jpg.daf9de454105c18b637f51fc8ec2b8dd.jpg

 

image068.jpg.3aea184853080d67fae3350442a9632a.jpg

 

image070.jpg.883fae4bcb7bdd25c682cdfc81b6b7b8.jpg

 

image076.jpg.c2edfa3657f6e06bf143f5efda15f3b7.jpg

 

15. Remove the fuel line from the three holders.

image078.jpg.bc0ce50cc973bf43b00bbaf034743b22.jpg

 

image080.jpg.53c5e9329108026c42c0d9b6c5838755.jpg

 

image082.jpg.edda13bd53b6ea57f6e33ce26d0a55d7.jpg

 

16. Remove these two bolts off the right front carb.

image084.jpg.43f634e47dd2c412b1d08e3c303012e3.jpg

 

image086.jpg.d493d11be41897fd1fec4377824fc4d4.jpg

 

NOTE: DO NOT REMOVE THESE TWO SCREWS! (these are to hold the cover on for the carb diaphragm)

image088.jpg.828fadb0623c4097f905c596b1748ae7.jpg

 

17. Loosen all 4 lower clamp screws on the bottom of each carb.

image090.jpg.c1762761f7aa41617e9ae871ad92a876.jpg

 

image092.jpg.8a6e68c2e7754fcc260cecd12aa69659.jpg

 

18. Now lift slightly on each side, left and right.

image096.jpg.7aa6be02730b63cc229142514e334cb6.jpg

 

image098.jpg.4cf319c171f1eb111e9ffd42c43775a2.jpg

 

image100.jpg.d800acfcedb19109da32b6c8681691f3.jpg

 

19. Start to pull from the left side about half way and then remove the fuel line that is on the rear middle of the carb cluster.

image102.jpg.63b0890e3203f3e0c41e159f3066242f.jpg

 

image104.jpg.d429e824639967744781dbaeaf9a9b4d.jpg

 

image106.jpg.08b2c0045ba38429c08d1b329531df30.jpg

 

20. Now the carbs are free from everything. Pull them the rest of the way out from the left side.

image108.jpg.156110f2fdc29b0e01062649937e073b.jpg

 

image110.jpg.2d42afc6afbe864954d4918922eb7781.jpg

 

21. Find a bucket and turn the carbs over to drain them.

 

22. Find your favorite work bench and place your carbs on it.

image112.jpg.60d6c9d3ea698f1d74f80406acd4b1c0.jpg

 

23. Do not forget to fill your intake manifolds with something that will not fall apart to keep the junk out of them.

image114.jpg.1a348dc751ef0f012cf79e5f838b742f.jpg

 

Just a side note for the float bowls. You will need a 4mm hex to remove the 3 screws.

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The cone shaped brass caps above the hex wrench come off for adjusting the mixing screws. Also, I want say PLEASE make any other comments or suggestions so that Don can add them to this write-up. I hope I explained this for you well.

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