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

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How to Remove Kawasaki Concourse Carbs
35 Steps
Supplies
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1
These are some of the tools you will need

These are some of the tools you will need

2
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

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3
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

4

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

5
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.

6
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.

7
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.

8
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.

9
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

10
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

11
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.

12
Here they are.

Here they are.

13
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.

14
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.

15
These are what are still holding it on without the screw

These are what are still holding it on without the screw

16
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

17
Yet another hose

Yet another hose

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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

19
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

20
I used a flathead to pry them up and away

I used a flathead to pry them up and away

21
Another hose

Another hose

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Another hose on the opposite side

Another hose on the opposite side

23
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.

24
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

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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

26
The first one I did the hard way

The first one I did the hard way

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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...

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

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

29
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.

30

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

31
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.

32
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.

33
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.

34
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

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.

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