*This setup uses only a single throttle control cable. Decelerate control and choke will not be used. Remove the storage unit from under the tank as this will not be used because of the carburetor clearance. If this manifold is being installed on a GL1200, the intake boots from a 1000/1100 must be used!
1. Remove intake boots, control cables, fuel lines etc. and remove existing carburetor setup.
Note: Remove carburetor assembly from left side of engine. Removal of the right front air piston cap will aid in the removal on some models.
2. Install existing intake boots onto new manifold making sure that the rubber flanges are in good condition.( Boots can be installed easier by warming in hot water for a few minutes) or use a little silicon grease on the inside of boot. This will also help in sealing against any air leaks
3. Install new manifold with the intake boots back on engine and reinstall the flange bolts. Tighten boot clamps ( 1” stainless 10-32 bolts may be needed because of the larger diameter runners)
4. Install the carburetor with the throttle control on the right side ( throttle cable bracket side) for left side installation a bracket will need to be made and attached to the underside carburetor bolt. This bracket can be made from a common straight bracket found in most hardware stores. 1/2" wide x 14 ga.
5. Locate positive electrical source ( any wire that goes through ignition switch) The fuse box under the top cover is the best location.
Connect 2 wires (Positive Terminal) upper screw on right side of box ( verify)
Connect 1 wire to the frame and the other to the carburetor itself.
One positive wire attaches to the electric choke, the other positive wire attaches to the air cut valve. Use correct size spade terminal connector. Note: to assure a good connection and watertight seal, remove plastic crimp from connector and solder connection. Replace with shrink tubing to assure watertight connection…recommended
6. Install fuel line, throttle cable, air filter (optional)
Note: You will need to change the cable end connector of the original throttle cable because the diameter will be too small to operate properly and may cause the cable to become disconnected from the throttle arm on the carburetor. A throttle cable end connector can be found at any auto part or motorcycle. The size is a 5/16” barrel type cable connector. Adjust cable assembly to reduce too much slack in the cable
7. Connect the larger vacuum line (from vacuum pump) to the larger vacuum connection on the carburetor and plug the small vacuum line as well as the small connection on the carburetor.
8. Turn ignition to the on position with the engine in cutoff position and crank the engine a few times to allow fuel into the carburetor.
9. Re-check all connections i.e. clamps, cables, and fuel lines
10. Start the engine and allow to idle for a few minutes.
11.Decelerator cable should be removed to avoid cable jamming, but is not necessary. Choke cable and decelerate cable can be tie wrapped inside tank cover
12. The carburetor should be factory set but will need some minor adjustments as needed. Please refer to the instructions included on fine tuning the carburetor.
13. The air breather (crankcase) should have a small breather filter attached
Reuse the chrome cover wire guides!!
The original chrome covers that include the spark plug wire guides can be reinstalled by turning the boot clamps with the screws on top. An angle bracket (simple 3/4" x 3/4" x 1/4" wide) can be attached under the boot screw with the brackets facing inward. Place the chrome cover piece over the brackets mark holes and drill bracket to secure chrome cover. I suggest using small chrome acorn nuts available in hardware or auto parts store. The holes not used will have dummy acorn nuts and the other will attach the bracket. This will secure very nicely and allow the wire guides and chrome trim to be used. Just a suggestion!
Questions? Call Bill