jdesignerw said:
I replaced the spark plugs and installed K&N Air Filters (http://www.amazon.com/gp/product/B000E7H458?psc=1&redirect=true&ref_=oh_aui_detailpage_o00_s00). I ordered a couple carb kits from a local shop that should arrive this Tues 11/3/15.
I attempted to check the points, but was unable to take the cover off. 2 of the 3 screws were stripped. I'm going to have to pick up a screw extractor to get those out. Does anyone have any tips for stripped screws?
I'm going to remove the carbs this week. I've got a Clymer manual, but if you have any tips let me know.
You'll need new jets. 2 of the Keihin secondary type main jet size 110! (EDITED from 105 which is the stock jet to 110 which is necessary for the K&N replacement filters)
Keihin secondary type main jet size 110 (SKU- 99202) From the JetsRus website.
Otherwise some of the site's sponsors sell them
Dime City for example.
http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-carburetor-parts-keihin-cv-secondary-jet-110-026-054.html
I would keep the original jets and clean them if they were mine. Since the "manufactured" kits nowadays are very hit-or-miss. Everything other than the mains that need to be larger that is!
Carbs are relatively easy to take out. Take off side covers, Unscrew one of the two 10mm cap nuts that run through both air filters (and double as side cover holders) then the long "stick" will come out. There's a single 10mm bolt holding the airboxes to the frame (top rear) and then the clamp to the carburetor needs to be loosened. The entire airbox comes out both sides. Note that there's a projection on the inside of each airbox that fits under the battery box in a little "tunnel" that's how they are connected and the rod goes through there for holding the side covers on.
Next up, I like to go to the left carb, loosen the choke lever umm..acuator bolt? You'll see how the little arm is attached to that side by a slotted bolt. Loosen that up and it should be able to slide off. It's a D key and you'll put it on the same way and then tighten the clamp down when reinstalling. Then you can loosen up the head side clamp and with another 10mm open wrench, loosen the throttle cables from each carb individually. I like to make sure the "locking" nut is in the same spot on both cables, as it makes synchronizing them far easier when you get her running. Then you'll have 2 separate carbs ready to be cleaned up!!
Lastly. Buy one of the $12 impact drivers. You will have a much better time with the old bolts on these machines. You can take off the adapter and use sockets if you wish, just make sure they are IMPACT sockets, because you don't want one of those exploding on you. I've never had any issues, but apparently bad things can happen if they aren't impact sockets. http://www.amazon.com/Powerbuilt-648002-2-Inch-Impact-Driver/dp/B004QO9FK2/ref=sr_1_9?ie=UTF8&qid=1446481324&sr=8-9&keywords=impact+driver+manual
Otherwise, find a drill bit that's about the size of the threads. Drill slowly until the head pops off. Take the cover off, and get a vice grip on the end of the bolt that is now sticking out. That usually works well for me.
Jet info from Herrdeacon in another thread: http://www.dotheton.com/forum/index.php?topic=18930.0