Hours or minutes

Removing the carburetors on models with the Yamaha FZR 1000 engine can be a time-consuming task taking several hours or a matter of just a few minutes.

The aluminum frame profiles on these models run above the engine, leaving only a few millimeters of clearance to the almost horizontally positioned carburetors. Behind the carburetor assembly, a rectangular profile is welded for frame reinforcement, which also has just a few millimeters of clearance.

To remove the carburetors, the hose clamps on the intake manifold must be loosened. As described, this can be difficult to nearly impossible, depending on the position of the clamp screw heads. In the best-case scenario, they are all mounted as shown in the lower image and can be accessed with an appropriate tool. If the clamps are twisted, the only option is to detach the engine from the frame and lower it, or lift the frame off the supported engine. This is a very time-consuming process involving many steps. Once you’ve had to do this, you will make sure all clamps are perfectly aligned in a row in the future.

The necessary tool for loosening the clamps in their installed state can be easily made. You will need:

• a 3 mm Allen key with a rounded head,
• a 6 mm aluminum tube at least 370 mm long, and
• a rotary knob or something similar.

Cut the Allen key before the angle, insert the long arm with the rounded head into the aluminum tube, and compress it in a vise. Then, attach the rotary knob to the other end, and you’re done.