Installing a Genesis Carburetor

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Written by Randy Fox (randysgym)   
Sunday, 06 September 2009

Mounting the Carb

The first step in mounting the Genesis carb is to remove the two screws on top of the carb, being careful of spring pressure from the large throttle return slide-spring inside. Tip: Use one hand to hold the top-plate of the carb down while you take out the top screws. This will keep the slide-spring from acting like a jack-in-the-box, and prevent any screw threads from getting stripped.

Gently pull the top-plate, the spring, the slide (including the metering needle) from the carb. The slide and needle are especially delicate. Even though they are made of tough, hardened materials, they are precision machined, and the very heart of the carbs awesome performance. Set them aside while you finish installing the carburetor body.

Next, insert the two 3/8"x 1.25"L mounting bolts, with washers, through the back side of the carb-mounting-holes of the manifold. Then slip the manifold spacer/s -- with o-ring/s installed -- onto the bolts. Be sure to orient the spacer/s with the o-ring/s facing toward the manifold.

Tip: Use a bit of silicone grease on the o-ring/s to help keep it/them in place during final positioning. This may not be necessary with some phenolic spacers that have built-in o-rings.
Tip: Before inserting the mounting bolts into the backside of the manifold, I used a little anti-seize compound on the end threads to reduce cross-thread potential and later difficulty in bolt removal.

Now smear some silicone grease on the supplied carb/manifold o-ring. Then fit it into the large o-ring groove at the back of the carb.

Next, carefully hold the carb up to the mounting bolts, and start screwing in the bolts using your fingers from around the sides of the carb, or in from the left side of the bike, using a socket with long extension. Tip: You will need to wiggle and adjust the carb as you do this, to be certain that you do not cross thread or bind-up the bolts.

Once both bolts are started, check that the o-rings of the carb and spacer/s are still in place; this is important. Then tighten the two mounting bolts to pull the carb up against the spacer/s and manifold. Torque the bolts to about 15-25 ft-lbs (fairly tight, but not so tight as to strip an aluminum thread in the carb).

Connecting the Fuel Hose

Next, guide the lower fuel hose segment to a good point along side the carb fuel inlet fitting, on the carb's left side. Tip: The fuel inlet fitting is movable so it can be better positioned. However, it has limits.

As you hold the hose along side the inlet fitting, mark the cut point on the hose. Then use a hose cutter or sharp knife to cut it at the mark-point. If you have too little space to make the cut, remove the hose, make the cut, and reinstall the hose -- or get a sharper knife. Tip: Better to cut a bit long, than too short.

Slip on a small hose clamp, work the hose fully onto the carb fuel inlet fitting, position the clamp, and then tighten it.

yamaha road star roadstar, genesis carburetor install

 
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