Rivera Primo Common Plenum Dual User Manual

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For Rivera Engineering's Dual 42mm Mikuni Carburetor kit

12532 Lambert Road, Whittier, CA 90606 (562) 907-2600

DISASSEMBLY

1.Disconnect the negative (-) battery terminal.

2.Turn the fuel petcock to the "OFF" position.

3.Remove the fuel tank from the motorcycle, or elevate the rear of the tank for better access to the intake manifold.

4.Completely remove the existing air cleaner assembly.

5.Disconnect the vacuum hoses and fuel hose from the carburetor.

6.Remove the carburetor assembly (and choke cable assembly) from the motorcycle. The throttle cable adjusters will need to be slackened to allow the cables to be disconnected from the carburetor. The Rivera dual-carb was designed to be operated with standard 1990 and later Harley-Davidson throttle cables.

7.Remove the intake manifold and clamps; these parts will not be reused.

INSTALLATION

1. INTAKE MANIFOLD

A. Attach the Rivera dual-carb manifold using the enclosed flanges and seals. The rear cylinder flange is marked with "R" and the front with "F". Place the flanges and seals onto the manifold and loosely attach the manifold to the cylinder heads using the stock bolts.

B. Attach the Rivera manifold support bracket to the cylinders in the appropriate method for your type engine:

Pre '92 engines use 2ea. 5/16" X 1 1/2" bolt s, 2ea. conical washer, and 2ea. 1/2" long spacers with 5/16" holes from this kit.

"92 and later engines (with 1/2" mounting/ breather holes) use 2ea. 1/2" hollow socket head bolts, and 2ea. 1/2" long vented spacers. Install the vented spacers as illustrated with the enclosed 5/16" ID hose.

SUPPORT BRACKET ATTACHMENT FOR

PRE '92 MODELS

SUPPORT BRACKET ATTACHMENT FOR

'92 AND LATER MODELS

C. Once you have determined the correct support bracket mounting for your model, attach the bracket loosely and secure the manifold to the support bracket with the enclosed 3/8" X 3/4" bolt, flat and lock washers.

NOTE

Center the intake manifold between the cylinder head and securely tighten the mounting hardware (i.e., manifold clamp bolts, support bracket bolts, and manifold bolt.

2. CARBURETOR INSTALLATION A. Place the enclosed carburetor spigot seals

onto the intake manifold spigots.

SAFETY PROCEDURES

NOTES, CAUTIONS and WARNINGS

Instructions in this manual preceded by these

words are very important.

NOTE

Means information that can make a job easier.

Means there is the possibility of damage

to the vehicle.

Means there is the possibility of personal

injury to yourself or others.

Read the installation instructions thoroughly prior to the installation of this Rivera dual-carb kit. All procedures should be followed exactly as described in this manual, paying particular attention to the following:

WARNING

1. THIS TYPE OF CARBURETOR REQUIRES THE USE OF A PULL/PULL THROTTLE ASSEMBLY to assure positive closing of the throttle valve (slide). The high vacuum encountered, as well as dirt ingested into the carburetor when running without an air filter, may hinder the throttle valve from closing promptly.

2. On installation, the THROTTLE CABLES SHOULD BE ROUTED FREELY (WITHOUT SHARP BENDS) BETWEEN THE THROTTLE TWIST GRIP AND THE CARBURETOR. The throttle cables should not be pinched by the installed fuel tank, and they should not be pinched, pulled or restricted by the motorcycle body work and/or the front fork assembly when it is turned through the full range of motion.

3. GASOLINE IS EXTREMELY FLAMMABLE. GASOLINE VAPORS ARE EXPLOSIVE. Before attempting to install or service your Rivera dual-carbs, please follow these fire safety procedures:

· Make sure your work area is well ventilated and free from any source of flame or sparks, i.e., appliances with pilot lights, such as water heaters, clothes dryers or space heaters, etc.

· Before removing the motorcycle fuel tank, be sure the fuel petcock is in the "OFF" position and the cross-over fuel line is well clamped. Clean up any fuel spills immediately.

4. Never look directly into the bores of the carburetors while the engine is running as injury may result from backfires.

A moderate degree of mechanical skill is required to properly install this dual-carb kit. If after reading these instructions you have any doubts about your ability to correctly install it we recommend that you have a professional install it for you. If you install the kit yourself we recommend that you also use the applicable Shop Manual for your model motorcycle as a reference.

TYPICAL TOOLS REQUIRED

These are the tools typically required to remove the stock carburetor and install the Rivera dualcarb kit.

1. Allen wrenches, 1/8", 5/32", 1/4" & 5/16"

2. Standard wrenches, 1/2", 9/16"

3. Diagonal cutters (dykes)

5. Slotted and #2 Phillips screwdrivers

5. Blue Loctite or equivalent

6. T25 TORX, '96-'98 models only

7. Shop Manual (for your model)

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WARNING

CAUTION

WARNING

vented spacers

spacers

conical washer

pre-92'

5/16" X 1 1/2"

bolt

manifold

support

bracket

vent hose

support bracket

hollow socket

head bolts

CHOKE CABLE INSTALLATION

4.THROTTLE CABLES

The Rivera dual-carb kit was designed to use the stock 1990 and later throttle cables. Before attaching the throttle cables, assure that they are in good operating condition and well lubricated.

A. Check to assure that the throttle cable adjusters are completely backed-off. Insert the end of the opening cable into the throttle wheel in the position indicated; do-not insert the cable housing into the cable bracket at this time. Insert the end of the closing cable in the remaining throttle wheel hole (hold the opening cable out of the way as necessary) and insert the cable housing into the cable bracket.

B. Insert the opening cable housing into the cable bracket. The cables overlap in the throttle wheel between the two holes but donot rub against each other during operation.

ATTACHING THE THROTTLE CABLES

C. Check the throttle for smooth operation. Open the throttle to the full open position and look into the bore of the carburetors to verify that the throttle valves are fully raised

out of the bores. If they are not, adjust the opening throttle cable until the throttle valves clear the bores.

D. Adjust the throttle "free-play" to approximately 1/8" as indicated by using the closing throttle cable adjuster to remove excess cable play.

ADJUSTING THROTTLE FREE-PLAY

4. HOSES A. FUEL HOSE - Connect the enclosed fuel

hose to the petcock and secure it with an enclosed hose clamp. Route the fuel line between the cylinders, below the intake manifold. Cut off any excess hose before attaching it to the carburetors. Secure the hose with the remaining enclosed clamp.

B. V.O.E.S - As required, attach the vacuum hose for the V.O.E.S. to the vacuum fitting on the closest carburetor (after removing the cap). If required, a longer piece of 3/16" vacuum hose is included in the kit.

C. VENT HOSE '92 AND LATER- Connect the remaining fuel hose to the open fitting on the vented space and secure with a hose clamp. Route the hose down between the engines and transmission. Cut the hose off flush with the bottom of the engine.

D. CARBURETOR DRAIN HOSES - Route the two carburetor drain hoses along the front push rod tube and in front of the crankcase. Secure them as necessary with cable ties from the kit.

Before inserting the carburetors into the intake manifold, make certain that the choke cable is positioned pointing downward, between the carburetors and intake manifold.

B. Insert the carburetor spigots into the manifold spigot seals with a slight rocking motion.

Putting a small amount of grease on the spigot seals will ease installation.

D. Secure the carburetors to the manifold by inserting the 3/8" X 5 1/2" bolt with the 3/8" lock and flat washers through the mounting hole in the backing plate and threading it into the manifold. As the mounting nut is tightened, assure that the carburetors are sliding into the spigot seals smoothly and evenly; wiggle the carburetors by hand to help the process. Tighten the mounting bolt until the capped carburetor fitting (close to the mounting bolt) contacts the intake manifold. The mounting bolt threads should bottom at the same time.

On rubber mounted engines, check the clearance between the gas tank and the carburetors, there should be a minimum of 3/8" at the closest point. If the clearance is less than this amount, place the 1/8" thick chrome spacer, included in the kit, between the intake manifold boss and the support bracket to create more gas tank clearance.

Having less than 3/8" gas tank clearance may allow the carburetors to contact the gas tank as the engine moves during normal operation.

It is very important that the carburetor

mounting bolt is not over-tightened to prevent damage to the seals.

3. CHOKE CABLE A. Route the choke cable knob up through the tri-

angular space in the manifold If the carburetor mounting bolt blocks the hole too much, back it out until the knob fits through then re-tighten the mounting bolt.

B. The nut that secures the choke bracket to the manifold is also the jam-nut for the carburetor mounting bolt. Place the 3/8" flat washers onto the carburetor mounting bolt and thread on the locknut, leaving enough space to slide the choke bracket onto the bolt. Slide the bracket onto the mounting bolt and tighten the locknut.

C. Slide the knob into the cable bracket slot as in the illustration and tighten the jam nut.

DUAL

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NOTE

CAUTION

support bracket

choke cable bracket

throttle wheel

attach opening cable here

opening cable

closing cable

3/8" lock nut

toothed washer

carburetor mount-

ing 3/8" X 5 1/2" bolt

3/8" flat washers

manifold boss

optional chrome spacer

intake manifold

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