I purchased a new choke cable because the one currently installed is bound up and wont do what it is supposed to do.

I recall a thread from several months ago where a poster, I believe it was 6066er, said that it is a 15-20 minute process.

Well... I started digging in thinking that if it can be done is 15 minutes, I should surely be able to do it without my service manual. 30 minutes later I gave up and cracked open the book. The book tells me that I need to take my f'ing tank off and remove the carb to do this.

SURELY it can't be that much work to replace the choke... especially if it can be done in 15 minutes.

So... what am I doing wrong?

 

I just put a 04 cv carb on my 95 sportster. There is no need to remove the gas tank. You have to remove the air cleaner assembly, disconnect gas line at petcock an loosen choke cable at attaching bracket. Once the is done you should be able to remove the vaccum line at back of carb an pull it out an replace choke cable. Throttle cables do not remove. Probably a hour maybe a little longer taking your time.

 

What he ^^^^^ said, but more like 30 minutes.

 

It only takes 6066er that long because his bike is wide open with not much in the way.

 

I just had mine replaced at the local indy. It took him less than 30 minutes, and he cleaned my aircleaner as well.

He took the carb off, but left the gas hoses connected. He did remove the throtle cables. The cable connection is on the top left hand side of the carb as you are facing the carb.

 

Watched a Harley mechanic do my 05 last week after I stripped the threaded post. Took him about 35 mins and he does it all the time. One hour + is a better estimate. Threading the cable in those tight spaces took the most time. That's probably why someone recommended removing the gas tank - more room to work.