Bandit Files: Bandit 1200 Carburetor Cleaning Part 3: Reinstallation

Reinstallation is mostly the reverse of removal.

Put a coat of light oil such as Tri-flow, WD-40, or 3-in-1, on metal-to-rubber contact surfaces, i.e. outside of carburetor air intake and throttle bodies, and inside of intake and air box boots. This will make it easier to reinstall carburetors and air box.

Reinstall rear throttle cable. This can be tricky.

Then reinstall front throttle cable and fuel hose.

Route fuel hose through rubber loop.

Push carburetors into intake boots. Rather than push them straight in, put the throttle bodies in at the bottom of the intake boots first with carbs tilted slightly upwards, then tilt them forward and down into the boots.

Slide the air box onto the air intakes. Be careful of pinching wiring harness on right side of bike. Screw in the intake and air box clamps.

Reconnect TPS and overflow hoses.

Position and bolt in air box.

Reconnect carb 4 vacuum hose.

Finally, reconnect and adjust the throttle cables. Make sure there is plenty of slack at the carburetor end, then reconnect at the throttle end.

Reassemble the throttle grip housing. Note guide hole in handlebar which should line up with guide post on the top housing.

Then insert throttle cables into guides at the carburetor end.

Tighten the cables about one turn each at the throttle end--turn the adjusters clockwise as you face toward the front of the bike.

Then tighten the carburetor side of the cables until there is a little freeplay in the throttle grip.

Finally reinstall the choke cable. I replaced it because it was frayed. To replace choke cable:

Using a cable lube tool and Tri-flow aerosol, lube the new choke cable from the carburetor end.

Disassemble the left side grip housing and remove the old choke cable from the choke lever. Clean and re-grease the handlebar under the choke lever.

Remove the old cable, and route the new cable under the left front panel to the carburetor. Should not be necessary to remove the panel if you're careful. Install the cable at the lever end, and reassemble the left grip housing.