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'48 Indian Motorcycle: Carburetor Disassembly and Rebuild The carburetor on our 1948 Indian gets removed, refurbished and rebuilt. From "Classic Rides" episode DCLR-303

In this project, DIY's Classic Rides host Craig Reynolds and motorcycle restoration expert Chris Matthews refurbish the fuel system on our project bike — a 1948 Indian Chief.

Chris and Craig prepare to refurbish the fuel system on the '48 Indian.

Rebuilding the carburetor

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In this phase of the restoration, the carburetor gets cleaned and upgraded. New fuel lines are bent and shaped for a custom fit, and installed. Chris also replaces the oil feed and return lines. Finally, old parts are stripped off in preparation for repainting, and the heads are dismantled and cylinders inspected.

	Chris uses the sandblaster to return used parts to almost like-new condition.

Basic tools used throughout this phase of the restoration:

standard automotive tools (socket-wrenches, screwdrivers, nut-drivers, torque wrench, etc.)
bike jack and stands
parts washer (or brake cleaner)
sand blaster
eye protection

Note: This is a summary of steps included in the restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

The carburetor rebuild kit contains replacement parts and gaskets.

Carburetor Restoration

One of the things Chris noticed during his test ride was that the bike stopped running. A few taps with a hammer got it going again, but obviously there was something going on with the carburetor. Part of the Indian's restoration is a rebuild of the carburetor using a rebuild kit that contains replacement parts, gaskets, etc.

Tools and materials:

standard automotive tools (socket-wrenches, screwdrivers, nut-drivers, etc.)
complete set of wrenches: SAE or metric
set of Allen wrenches: SAE or metric
set of screwdrivers
pliers
parts washer
carburetor rebuild kit

	Figure A
	Figure B

Carburetor Disassembly and Cleaning

• The carburetor first has to be removed from the bike. In the case of our Indian, it's held on with three flat-head screws. Use a screw driver to remove the screws (figure A) and the carburetor comes right off (figure B).

• Before working on the carburetor, be sure to drain any remaining gas into a safe container and dispose of properly.

The carburetor float-bowl

• The float bowl is removed first. Unscrew the retaining bolt at the bottom and the bowl slides off.

• Use a parts washer, or brake cleaner if a washer is not available, and completely spray down the carb. This will remove any dirt of sediment and also help to dry up any residual gas.

• The rebuild kit will contain detailed instructions, and an exploded diagram of the carburetor. Always refer to this if you get lost during the process.

• The throttle plate is held to the shaft by two screws. Remove these with a screwdriver, rotate the throttle shaft slightly and the plate will drop out.

• On the end of the shaft is the throttle lever and idle adjustment screw. Loosen its clamp screw with a screwdriver, remove the adjustment assembly, and the throttle shaft can mow be pulled out.
  

  	Figure C
  	Figure D

• On the other end of the carb is the choke plate. Just like the throttle plate, it is held on with two screws. Rotate the shaft slightly and remove the screws.

• Remove the choke shaft stop with a wrench and the choke shaft will slide out.

• There is a check ball that holds the choke position. Be careful to catch it when the choke shaft is removed.

• Once the choke shaft is removed, the venturi, will slide out.

• With the carburetor disassembled, as part of the complete refurbishment Chris took it to the sandblaster to thoroughly clean it (figures C and D), leaving it practically new looking.
  
  
  

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  ALSO IN THIS EPISODE:
  	'48 Indian Motorcycle: Carburetor Disassembly and Rebuild
  	'48 Indian Motorcycle: Fuel Lines Replacement
  	'48 Indian Motorcycle: Oil Lines Replacement; Gas Tank Removal
  	'48 Indian Motorcycle: Heads Removal and Cylinder Inspection