Disassembly

Fig. 3 Exploded view of Mikuni carburetor. Non-feedback carburetor shown, Feedback carburetor similar:

1. Compress clamps and remove water hose from choke assembly, Fig. 3.
2. Drill out staked portions of choke cover side screws.
3. Using a small hammer and punch, gently tap edge of choke cover top screw counterclockwise until screw is removed, then remove cover.
4. Note relationship between punched mark and scribed line on choke pinion plate. During assembly the line and punch mark must be aligned.
5. Remove E-clip from throttle opener link, then the throttle opener attaching screws and throttle opener.
6. On standard models, remove ground wire from fuel cut-off solenoid, then remove attaching screw and the solenoid.
7. On all models remove throttle return spring and damper spring.
8. Remove E-clips and choke unloader link from carburetor.
9. Disconnect vacuum hose and link from vacuum chamber.
10. Remove mounting screws and the vacuum chamber.
11. On feedback models, remove throttle position sensor mounting screws and the sensor.
12. On all models, remove vacuum connector hoses.
13. Disconnect accelerator operating rod link from throttle lever.
14. Remove air horn mounting screws and separate air horn from carburetor body.
15. Slide out float pivot pin and remove float assembly.
16. Remove and discard air horn gasket.
17. Unscrew retainer and remove needle seat and screen assembly, being careful not to lose shim from under needle seat assembly.
18. On feedback models, disconnect solenoid wiring and unscrew solenoids from air horn.
19. On all models, remove venturi retainers and venturis, discard O-rings, and mark venturis so that they can be installed in proper position.
20. Remove primary and secondary main jets from their pedestals, noting jet numbers for proper installation.
21. Remove pedestals and discard gaskets.
22. Remove bowl vent solenoid mounting screws, then separate bowl vent from air horn and discard O-ring and seal.
23. On standard models, remove coasting air valve attaching screws and separate valve from air horn.
24. On all models, remove enrichment valve attaching screws, then separate valve from air horn and remove jet.
25. On all models, remove screw, lock and primary jet set.
26. Remove screw, lock and secondary jet set.
27. Remove primary and secondary air bleed jets from top of air horn, noting their sizes for proper installation.
28. Carefully invert air horn and drop out pump weight, check ball and hex nut.
29. Remove accelerator pump screws and separate pump from air horn.
30. Remove jet air control valve screws and separate valve from throttle body.
31. Remove E-clip from sub-EGR lever, then carefully slide pin from lever and sub-EGR valve. The lever is under spring tension caused by a steel ball and spring in sub-EGR valve which prevents play between sub-EGR valve and lever. Care should be taken not to lose ball and spring when removing lever.
32. Remove valve from throttle body.