How to remove a Virago 535 carburettor

Written by jenny roberts Google
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How to remove a Virago 535 carburettor
Keep your motorcycle fully maintained. (Jupiterimages/Photos.com/Getty Images)

The Virago XV535 manufactured by Yamaha between 1987 and 2003 is a middleweight cruising motorcycle, designed to look like an American chopper with its V-Twin engine and chromed body styling. Regular maintenance of the carburettors will ensure smooth running and good fuel economy. Removing the carburettors is not an easy job due to their location under the fuel tank, but it is a worthwhile one you can undertake at home with just a few basic tools and can save you from costly garage bills.

Skill level:
Moderately Challenging

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Things you need

  • Socket set
  • Screwdriver
  • Pliers
  • Pry bar
  • Spanners
  • Rubber gloves
  • Service stand

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Instructions

  1. 1

    Leave the motorcycle to cool fully before securing in an upright position using either the centre stand (if fitted) or a service stand.

  2. 2

    Remove the seat by unlocking the seat latch and removing the fixing bolts, clips, washer and clevis pin. Remove the plastic side covers from both sides of the frame by first undoing the fixing bolts, then releasing front and rear tabs, undoing screws from the edge and lifting off the covers. Also remove the cover to the electrical panel which is found underneath the seat bar.

  3. 3

    Unscrew the mounting bolts located near the steering pivot and at the base of the fuel tank. Clamp the fuel hoses to prevent petrol leaking before carefully pulling them off both sides of the tank and then remove the fuel tank. There are no fuel hoses attached on the false fuel tank of the Virago XV built between 1987 and 1989.

  4. 4

    Use a screwdriver to remove the wiring harness from the frame which is secured by clips. Using pliers, pull off the fuel hose from the inlet spigot on the carburettor.

  5. 5

    Release the clamps holding the air filter intake hose. This can be found at the top of the carburettor. Also release the intake hose clamps from the bottom of the carburettor. Pry the air filter and intake hoses from the carburettor by gently using a large flat screwdriver or small pry bar; care must be taken not to damage the hoses during this process.

  6. 6

    Remove the carburettors from the left hand side of the engine by lifting them upward and out of the intake housing.

  7. 7

    Disconnect the throttle cable which is located in the centre of the carburettor. This is done by pulling the cable out of the cable holder, removing the inner cable from the cable holder through the slot that is cut into it, then finally pulling the end of the cable out of the carburettor throttle pulley. The carburettor should now be free from the motorcycle.

Tips and warnings

  • Wear protective gloves to avoid getting any petrol on your skin which can be an irritant.
  • There have been variations over the years to the Virago 535 so if you are unsure of anything refer to the handbook.
  • Petrol is extremely flammable so be careful when working on any part of the fuel system.

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