1. Make sure bike is cold, get something clean to contain the old coolant (you can reuse it if you wish), drain the coolant by removing the hose clamp from the pipe side radiator hose (where it connects to the motor).
   
   
2. Remove the radiator hose completely (pipe side). Remove other side radiator hose as well as the 90 degree outlet from the front of the motor(8mm wrench).
   (See fig. 2)
   
   
3. Remove silencer (6mm allen). Unbolt header from engine(12mm wrench) be careful not to damage the gasket, pull the header off from right side of the bike.
   
   
4. Install new header pipe with gasket to the engine (do not completely tighten the bolts) Install ALBA silencer and use the supplied 12mm flange bolts in place of the stock 6mm Allen bolts. Once the complete system is on the bike, tighten all the pipe bolts.
   
   
5. Install 90 degree outlet (figure 2) and radiator hoses. Fill with coolant to manufacturers specifications.
   
   
6. You should rejet with this pipe kit, once you do that warm the bike up for 15 minutes giving the bike some gas a few times make sure there are no leaks and shut off, let cool, then check the coolant level.

( figure 1)
Team Alba Z400 Pipe Kit

( figure 2)
90 degree radiator outlet

To avoid losing any small parts, lay a towel on top of your work bench to work on or use a tray of some kind.

1. Turn off the fuel, remove seat, front fender, air box snorkel and fuel tank
   
   
2. On the top of the carburetor, remove the black top with the two phillips head screws in it. Be careful there is a spring beneath.
   
   
3. Once the black cap is off, remove the rubber diaphragm containing the slide and needle.
   
   
4. With some needle nose pliers, gently pull the gray rectangle straight out of the slide. Over your towel or tray, turn the slide over, the needle will fall out. On the needle you should have a gold shim, then a white plastic spacer, an e-clip then a small shim. If you don't have them all, look in the bottom of the slide, you don't want these parts sucked into the motor later! Take the e-clip off the needle and save it as well as the rest of the shims.
   
   
5. Install the old E-clip on the new needle at the 3rd notch down from the top. Replace the shims and spacer in the same order that you removed them. You can now insert the needle back in the slide and replace the gray keeper with the spring.
   
   
6. Place diaphragm back into carb making sure it does not get torn or folded. Replace spring and black top, install the two phillips screws.
   
   
7. On the carburetor there is the fuel line and three other hoses, remove them. Loosen the hose clamps on the front and the back of the carb. You should be able to pull straight up on the carb to get it out. The throttle cable is going to hold you up so you will have work on the carb over the quad.
   
   
8. Get a rag, turn the carb upside down, unscrew the four float bowl screws, gas will start to leak so keep that rag handy
   
   
9. Replace the main and pilot jet, there is one jet (the choke circuit) that you will not touch. Replace float bowl and float bowl screws
   
   
10. Remove plug from fuel screw with a drill and a small drill bit, the plug should come out once you start to drill you only need to drill in a 1/8 of an inch. Don't be nervous, there is nothing to it! If it does not come out then use some needle nose pliers to pull it out. Set the fuel screw by screwing it in all the way and then backing it out 3 turns.
    
    
11. Install carb, replace fuel tank on quad, install the four hoses, tighten up your hose clamps. Make sure you throttle is not sticking, turn on fuel.
    
    DOUBLE CHECK EVERYTHING
    
    
12. Start your bike up and blip the throttle a few times, check for leaks and that everything is OK.
    
    
13. Bolt down fuel tank , install airbox snorkel (optional) and front fender