When it comes to custom builds, each Harley Davidson is different. If you want to try your hand at a little at-home motorcycle mechanics, make sure to have all the right information before you get started, as taking apart a Harley is simple, but putting it back together – not so much. While Harley Davidson Shovelheads have been modified over the years, the installation process for the Super E/G Carb remains fairly similar between models.
If you’ve never installed one before, hold onto that instruction manual! Without a manual, it will be like going in blind constructing a PAX Wardrobe from IKEA. So listen up, if you’re thinking “she’ll be right” – you’d be wrong. Read the instructions, this is not a craft project, it’s a Harley Davidson – you won’t be laughing when it falls apart on the road. American Motorcycles in Victoria Park specialise in reproduction and aftermarket motorcycle parts, custom rebuilds and pre-owned motorcycles. S&S Cycle are one of our parts suppliers, and have produced a video guide for their new Super E/G Carb.
FIRST THINGS FIRST
Before beginning, you may need to purchase a set of throttle cables depending on whether your motorcycle model was built before 1981. The earlier model Harley’s will only have a single throttle cable that will need to be modified to two so the throttle can be opened and closed. Next, you will need to remove the Stock Carb and manifold. Take the air cleaner back plate and rest it with the open side facing upwards in order to install the enrichment lever, taking care to place the parts on in order. Listen carefully for the variations in model years for the differences in the crankcase cleaner and air breather.
ASSEMBLING THE INTAKE MANIFOLD
Shovelheads can use either of two types of manifolds to fit the two types of heads: o-ring heads or rubber band style heads. Careful to note – o-ring heads are very sturdy and durable, but rubber band style heads can split and leak if the carb is not properly supported. This Harley uses an o-ring carb kit – always make sure to check which style of carb kit your Harley requires before ordering your vintage part, as the bike may have been modified.
It is always best practice to clean and inspect the intake port to ensure the sealing surface is adequate. If there is damage, replace them or you may find your motorcycle suffers intake leaks, erratic idling and, in more serious cases, engine damage. Assemble the manifold and make sure the tightening nuts remain accessible to make securing the part far easier. Allow a little slack to allow for adjustments once the carb is installed. Bolting the manifold into place will differ based on engine model and year.
INSTALLING THE SUPER E/G CARB
Reset the Carb to its factory settings – this will allow the bike to start and remain idling while you make final adjustments. Install the throttle cable guide and screw the bracket to the Carb. Place the supplied o-ring into the insulator block and mount to the manifold. Next you will need to hold the Super E/G Carb up to the manifold and turn the screws carefully into place.
MAKE SOME ADJUSTMENTS
Adjust the throttle cables, making sure they continue to snap back into place – this shows the cables are working to correctly open and close. This is a key safety feature, so if you are unsure, make sure to have them inspected by an experienced motorcycle mechanic. Next, install the fuel line, cutting the fuel hose to the correct length so it easily reaches the petcock without kinking and cover with its protective covering, making sure the line doesn’t come into contact with any hot engine parts followed by the overflow line.
Next, install the air-cleaner back plate you prepared earlier, place in the gasket and attach to the carb through the enrichment lever. Double check the enrichment level can move freely by lifting it upwards and downwards, then tighten the back plate screws. Use washers to eliminate any gap between the plate and the supporting bracket, then tighten into place before placing on the air filter. Finally, add the teardrop cover filter, screwing everything into place. Once the Super E/G Carb is in position, go back and tighten the manifold clamps properly.
FINAL CHECKS AND INSPECTIONS
Conduct a final leak inspection by turning on the fuel petcock and checking all connections for problems before starting the ignition. Turn the bike handles from left to right to test the throttle for a snapback. The crew at American Motorcycles are experts when it comes to aftermarket, reproduction and custom motorcycle parts and repairs. Ask the team for advice on which parts your model requires. Alternatively, if you’ve finished installing a new vintage part on your Harley or custom chopper, bring your motorcycle in for a service or safety check-up by an experienced motorcycle mechanic.
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