1981 GS650g Carburetor Removal/Cleaning

[tkathalynas69]

Hi, I'm new to not only this site but motorcycles in general. I bought my bike last spring and I rode it a little through the summer, and eventually after little tweaks that I did I was finding more and more things that were possible problems for the bike. The biggest problem my friend and I found right now is that when or if the bike starts (having some issues starting as well) the bike is running only on 3/4 cylinders. One of the headers was cold while the others were fairly hot, so that just showed me that obviously somethings going on with that. My friend who has a lot more experience with engines said we could probably start by doing a carb cleaning and see if that sorts anything out or makes any improvement. My question right now is just how to remove the carburetor? I have the tank off and the air filter box, but I still can't figure out how to slide the filter part that's connected to the back of the carbs out. The whole assembly is really snug, and I just need some help with removing it. As well as any wiring diagrams because both my friend and I were shocked at the way some of the wiring had been done, and I just want something to look back at and make sure connections are being made where they should be.

Thomas.

 

[Nessism]

http://members.dslextreme.com/users/bikecliff/

You can get a service manual and a copy of the carb rebuild tutorial from that site. Don't shortcut the cleaning process or there is a very good chance you will be back doing the job a second time.

To remove the carbs you need to loosen the screws holding the airbox to the frame. Then loosen the clamps between the carbs and the airbox and slide the airbox back as far as possible. Last thing is to loosen the carb clamps in the front of the carbs and slide the carbs back and then out. Watch which way the throttle cable is routed and pull the carbs out the appropriate side, typically the RH side of the bike.

 

[tkathalynas69]

http://members.dslextreme.com/users/bikecliff/

You can get a service manual and a copy of the carb rebuild tutorial from that site. Don't shortcut the cleaning process or there is a very good chance you will be back doing the job a second time.

To remove the carbs you need to loosen the screws holding the airbox to the frame. Then loosen the clamps between the carbs and the airbox and slide the airbox back as far as possible. Last thing is to loosen the carb clamps in the front of the carbs and slide the carbs back and then out. Watch which way the throttle cable is routed and pull the carbs out the appropriate side, typically the RH side of the bike.

When I got to loot at the wiring diagram it says the domain is not found.. So I'm not sure what that's all about.

 

[tom203]

Before we get into the fun of carb extraction.. which cylinder was not getting its header pipe hot? Sitting on bike, #1 cylinder is on extreme left (under the clutch hand lever).

"I still can't figure out how to slide the filter part that's connected to the back of the carbs out. The whole assembly is really snug"

the airbox (the thing that connects to carb intakes) won't want to leave the bike frame. You need to remove bolts holding the airfilter box on and slide airbox and airfilter box towards rear of bike. Lots of stuff will interfere with this movement, so move wiring, loosen rear fender,etc. to get about 1/2 inch or so of travel- this will let airbox pop out of carb throats. Then you can get carbs out of intake boots, unattach cables,etc and slidecarb gang. Take pics to show where stuff goes BEFORE
removal.

 

[Nessism]

When I got to loot at the wiring diagram it says the domain is not found.. So I'm not sure what that's all about.

Try downloading the service manual for your bike, there is a wiring diagram within.

 

[tkathalynas69]

The cylinder that was not getting hot was #3 from the left.

 

[tom203]

When I got to loot at the wiring diagram it says the domain is not found.. So I'm not sure what that's all about.

yes, try this. If too small,send me a PM and leave an email address- it will show up bigger than on forum for some reason. The diagram is similar to the shaft 650

 

[tkathalynas69]

Still having trouble pushing everything back because it seems like it's butted right up against the frame..

 

[BigD_83]

That is about as far back as you are going to get it to move. At this point, you should be able to pull hard backwards and compress the boots enough to pull the carburetors out of the intake boots. Of course, this is much easier said than done with the 36 year old rubber boots that are on the bike, but be persistent, it is possible. From your picture, it looks as if the carbs are almost out of the intake boots now.

Before I replaced the boots on the 650, I had to resort to using carefully placed ratchet straps to pull the carbs back.