How to Remove Kawasaki Concourse Carbs

Start the Guide
Remove Kawasaki concourse carbs

How to Remove Kawasaki Concourse Carbs

My bike is in need of some serious work. The carbs are first with a valve adjust to follow

481 Views
Step 1 of 35
These are some of the tools you will need

These are some of the tools you will need

Step 2 of 35
First off you have to remove the tank. To do so take off the seat to get to the two bolts that hold the tank on

First off you have to remove the tank. To do so take off the seat to get to the two bolts that hold the tank on

Step 3 of 35
Here are the 10mm bolts. One of mine broke and I need to drill it out... some other guide.  You will also need to disconnect this hose

Here are the 10mm bolts. One of mine broke and I need to drill it out... some other guide. You will also need to disconnect this hose

Step 4 of 35

You will need to shuffle the tank about to get to the hoses underneath. To do so lift from where you removed the bolts up and back. This should free the tank from its mount

Step 5 of 35
This is the fuel pitcock. Turn it to the right and off position so fuel won't spill anywhere.

This is the fuel pitcock. Turn it to the right and off position so fuel won't spill anywhere.

Step 6 of 35
This is the correct off position. I had it turned the wrong way and made a small puddle.

This is the correct off position. I had it turned the wrong way and made a small puddle.

Step 7 of 35
Grab your pliers and slide this clamp down the hose then remove the hose.

Grab your pliers and slide this clamp down the hose then remove the hose.

Step 8 of 35
Disconnect the fuel gauge. Be careful to pull on the connector and not the wires.

Disconnect the fuel gauge. Be careful to pull on the connector and not the wires.

Step 9 of 35
Here's two more hoses. Get the pliers again. Move the clip and slide em off.  Probably gonna be some fuel spilling out

Here's two more hoses. Get the pliers again. Move the clip and slide em off. Probably gonna be some fuel spilling out

Step 10 of 35
Mine needed some encouragement.  Try not to puncture or tear the hose when removing. These ones don't have much play

Mine needed some encouragement. Try not to puncture or tear the hose when removing. These ones don't have much play

Step 11 of 35
Now that it's off you can get to the carbs. I removed the side plastics a long time ago so if yours are still on the you will need to remove both sides.

Now that it's off you can get to the carbs. I removed the side plastics a long time ago so if yours are still on the you will need to remove both sides.

Step 12 of 35
Here they are.

Here they are.

Step 13 of 35
You'll need to remove these guys. One on either side. Remove this screw and pull towards yourself with your right hand.

You'll need to remove these guys. One on either side. Remove this screw and pull towards yourself with your right hand.

Step 14 of 35
To keep from losing fasteners I like to put them back where I took them.

To keep from losing fasteners I like to put them back where I took them.

Step 15 of 35
These are what are still holding it on without the screw

These are what are still holding it on without the screw

Step 16 of 35
This is the air box. Two 10mm bolts and the carbs keep it trapped. You don't need to remove these, but I'm planning on getting rid of it in favor of 4 individual air filters

This is the air box. Two 10mm bolts and the carbs keep it trapped. You don't need to remove these, but I'm planning on getting rid of it in favor of 4 individual air filters

Step 17 of 35
Yet another hose

Yet another hose

Step 18 of 35
Here we go. The carbs are held in place by clamps on both sides. Use a Phillips on the engine side and loosen these up. You can reach two per side

Here we go. The carbs are held in place by clamps on both sides. Use a Phillips on the engine side and loosen these up. You can reach two per side

Step 19 of 35
On the air box side just slide these elastic type clamps towards the air box

On the air box side just slide these elastic type clamps towards the air box

Step 20 of 35
I used a flathead to pry them up and away

I used a flathead to pry them up and away

Step 21 of 35
Another hose

Another hose

Step 22 of 35
Another hose on the opposite side

Another hose on the opposite side

Step 23 of 35
This Is the choke control I believe. Get your pliers on the cable and slide the bar with your finger as you maneuver the cable free.

This Is the choke control I believe. Get your pliers on the cable and slide the bar with your finger as you maneuver the cable free.

Step 24 of 35
You can see the notch that the cable fits through in this shot

You can see the notch that the cable fits through in this shot

Step 25 of 35
Now you have to move the silicone hoses on the air box out of the way

Now you have to move the silicone hoses on the air box out of the way

Step 26 of 35
The first one I did the hard way

The first one I did the hard way

Step 27 of 35
Here it is out of the box. It is much easer to push it back inside. FYI...

Here it is out of the box. It is much easer to push it back inside. FYI...

Step 28 of 35
Here's the easier way. Still small work space though

Here's the easier way. Still small work space though

Step 29 of 35
This is the inside of the air box. Remove these two screws. Pull this plastic wedge out then the air filter. Now you can pull from the inside as you push from the outside.

This is the inside of the air box. Remove these two screws. Pull this plastic wedge out then the air filter. Now you can pull from the inside as you push from the outside.

Step 30 of 35

After the last silicone hose is pushed out of the way you can pull the carbs away from the engine and allow it to hang from the throttle cables

Step 31 of 35
These ones were a pain. They are the throttle cables and there are two. One to remove the fuel when you let go and the other to add it when you accelerate.

These ones were a pain. They are the throttle cables and there are two. One to remove the fuel when you let go and the other to add it when you accelerate.

Step 32 of 35
To get these free you need to loosen the nut directly above my finger. Loosen the top rusty one and slide it out of the channel holding it in place then remove the cable like the choke one.

To get these free you need to loosen the nut directly above my finger. Loosen the top rusty one and slide it out of the channel holding it in place then remove the cable like the choke one.

Step 33 of 35
Label them so when you reinstall them you don't  put them on backwards.

Label them so when you reinstall them you don't put them on backwards.

Step 34 of 35
The second cable was much harder than the first. Be patient and just repeat the last step and voila its free. The bowls will be full of fuel too so empty that out before taking it to your workbench

The second cable was much harder than the first. Be patient and just repeat the last step and voila its free. The bowls will be full of fuel too so empty that out before taking it to your workbench

Step 35 of 35
Finally plug the engine openings so nothing makes it's way inside.

Finally plug the engine openings so nothing makes it's way inside.

Start Over

0 Comments
Supplies

Screwdriver

Wrenches

Towel

10mm socket and wrench

Pliers

Gojo

Be first to comment on this guide.

Be first to comment on Step 1.

Be first to comment on Step 2.

Be first to comment on Step 3.

Be first to comment on Step 4.

Be first to comment on Step 5.

Be first to comment on Step 6.

Be first to comment on Step 7.

Be first to comment on Step 8.

Be first to comment on Step 9.

Be first to comment on Step 10.

Be first to comment on Step 11.

Be first to comment on Step 12.

Be first to comment on Step 13.

Be first to comment on Step 14.

Be first to comment on Step 15.

Be first to comment on Step 16.

Be first to comment on Step 17.

Be first to comment on Step 18.

Be first to comment on Step 19.

Be first to comment on Step 20.

Be first to comment on Step 21.

Be first to comment on Step 22.

Be first to comment on Step 23.

Be first to comment on Step 24.

Be first to comment on Step 25.

Be first to comment on Step 26.

Be first to comment on Step 27.

Be first to comment on Step 28.

Be first to comment on Step 29.

Be first to comment on Step 30.

Be first to comment on Step 31.

Be first to comment on Step 32.

Be first to comment on Step 33.

Be first to comment on Step 34.

Be first to comment on Step 35.