Pair Valve Removal Made Easy
|by "Moccasin" Mike|
For the C50 Boulevard
NOTE** Removal of the pair system on the C50 Boulevard
is exactly the same procedure as its older cousin, the Volusia
800, with the exception of the electronic actuating solenoid that is
used on the C50. This page will show you the solenoid, and what to do with it,
in step 1. The remainder of the instructions are identical to the Volusia.
Many thanks to my cyber friend "NeutronJon" for the great photos for this page!
Click on any of the photos for larger format versions.
8mm Box Wrench (the longer the better) / 10 mm Socket and Wrench / 12 mm Combination Wrench
Long #2 Phillips Head Screwdriver / Gasket Sealer / Lots of Patience
Click here to see a Service Manual diagram of the complete Volusia Pair System,
for a visual reference to the following instructions.
NOTE** If you are using a removal kit by "Moccasin" Mike, be aware that these kits are packaged to be used universally on the LC, Marauder and Volusia and C/M series bikes. YOU WILL HAVE KIT COMPONENTS LEFT OVER!
All metal components of the removal kits have been "Blackened" with satin finish engine paint, and baked at 400 degrees to match your engine block. Some damage to paint may occur during shipping and/or installation.
|STEP 1. REMOVE THE COVER AND PAIR VALVE ASSEMBLY (Click the photos for larger views)|
|Photo showing the small "pillbox" on the left side of the C50/M50 engine. Remove the two acorn nuts to remove the cover.|
|With the "Pillbox" cover removed, the pair valve assembly is exposed. The hose to the left is the air intake hose to the valve assembly. The two air delivery hoses (to the cylinders) are attached to the backside of the assembly, and the gold colored film canister size piece to the right is the electronic solenoid.|
|Looking at it from the rear of the bike, you can see the wiring that runs to the solenoid, and the two Phillips head screws that hold the solenoid to the valve body.|
|Remove the solenoid (shown here being held) from the valve
body and hang it off to the side while the remainder of the system is
removed. The solenoid must be retained and connected to the bike's
harness connector to avoid engine fault codes during startup. Use the
two supplied plastic zip ties to secure it up out of site, under the tank. This can be done by looping the zip ties over the main wiring harness
and through the solenoid screw holes, then cinch them up to the main
harness or to the bike's framework..
You may find it easier and more secure to relocate the solenoid behind the right side neck cover (with the ignition switch). Thanks to Bob Warren for that tip!
An alternative to retention of the solenoid is replacing it with a 4.7k-Ohm 1/4 Watt inline resistor. You can learn more about that HERE.
|Remove the valve assembly and bracket by removing the two bolts that attach it to the cylinder casings. Your kit will come with small filler bolts to put back in the attachment holes.|
|With the valve and bracket assembly loose, you can now access the two air delivery tubes on the backside.|
|If you simply wish to block, but not remove the system, you
can insert a pair of round head (phillips or allen) screws headfirst into
the rubber tubing. The tubing can then be replaced onto the valve nipples
for reassembly, and the screws are easily removed later with a pair of
needle nose pliers.
For complete system removal, continue to Step 2.
LEAVE THE AIR BREATHER OFF FOR NOW, AS YOU WILL NEED THE ROOM
The next steps are recommended to get the room
needed to work, especially for people with average to large hands.
Put the 12 mm bolt back in for the horn and tighten up.
Simply reverse the procedure outlined above.
Happy Wrenching!!! J
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