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.

Recommended Tools
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!

 

 

NOTE:
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.

STEP 2. REMOVE THE AIR BREATHER ASSEMBLY.
Remove the two Allen screws on the air breather cover and remove air filter.

Remove two Allen screws from the case on the top.
Loosen the hose clamp on the top of the air breather body with the #2 screwdriver.
Pull out and down on the body and the hose will come with it. (be careful with it, it is tight, but it will come out)
Remove hose from back of air breather body and put the large cap from the kit on the port . Then use the clamp from the original hose to secure it to the port.

LEAVE THE AIR BREATHER OFF FOR NOW, AS YOU WILL NEED THE ROOM

STEP 3. REMOVE THE REAR AIR DELIVERY TUBE
After removing the rubber tubes from the top of both chromed air tubes (see diagram at top of page),
Loosen the two chrome bolts with 8mm box wrench and remove the bolts.
The chrome air delivery tube and flange will feed out the left side of the bike.
It does not come out straight so turn it and twist it as it comes out . It takes some firmness , but not brute force.
Apply small amount gasket sealer around hole.
Apply small amount of gasket sealer to gasket and adhere to cover plate (from the kit).
Apply small amount of gasket sealer to chrome bolt threads and start the bolts in the holes.
Tighten as far as possible with fingers and use box wrench to finish up.

STEP 4. MAKE ROOM FOR REMOVAL OF THE FRONT TUBE

The next steps are recommended to get the room needed to work, especially for people with average to large hands.
Remove the two Allen head bolts that hold the exhaust to the head and move the pipe out of the way.
Remove the 12 mm bolt that holds the horn bracket to the frame.
Remove the radiator cover by pulling out from the bottom and lifting off the tabs at top
Remove the three 10 mm bolts that hold it on. Two at top, one at bottom.
Remove the three 10 mm bolts from the cooling fan and push it down a little.

STEP 5. REMOVE THE FRONT AIR DELIVERY TUBE
With the box wrench loosen the two 8mm chrome bolts as far as possible
Now squeeze your hand between the frame and the radiator and put the 8mm nut driver tip on the chrome bolts and take them out.
Remove the air delivery tube (same twisting and turning as the rear).
Repeat the gasket sealer steps for the back flange.
Put the chrome bolts back in and tighten them by hand as far as you can and use the box wrench to finish it up.

Put the 12 mm bolt back in for the horn and tighten up.
Put the two 10 mm bolts back in the cooling fan and tighten up.
Put the three 10 mm bolts back in the radiator and tighten up.
Put the radiator cover back on (top first).

STEP 6. RE-INSTALL THE AIR BREATHER

Simply reverse the procedure outlined above.

STEP 7.
TAKE PICTURES AND SHOW ALL YOUR FRIENDS!!

Happy Wrenching!!! J

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