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79 GS550 Airbox issue

  • Thread starter Thread starter The Road Warrior
  • Start date Start date
T

The Road Warrior

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I have a 79 GS550 project bike and I'm having an issue with the plastic airbox that attaches to the carbs. The carbs fit into the rubber boots on the engine side just fine but I've always had difficulty attaching the plastic airbox to the carbs.

It just seems like the boots that are on it should be a little longer. I can get them on somewhat but when I go to tighten one of the clamps on one side, the other side slips off easily. I've also unscrewed the filter box from the frame so that I can move the plastic housing around a little better (closer toward the carbs). Still doesn't seem to help much. I'm assuming that I want the carbs pushed as far back into the intake boots (and clamped) as far as they will go, forming the best possible seal on the engine side, correct?

It's really frustrating. Any advice or tips that would do the trick? Thanks!

A picture of what part I'm talking about (I know this one is not the correct year).
 
You may need new boots on the air box. They get brittle with age and don't like to stay in place. As far as slipping them all the way on, there are little tangs on the carb throats that act as a stop for the boots. They need to be seated up against those little "ridges/stops".
Also...if you're using the original clamps, it may be time for a new set. The old ones just don't seem to tighten up correctly, allowing for the seated boots to slip off.
 
Thanks. Is there a part number for just the boots? I don't think I have seen them for sale on Ebay by themselves.

I went to the hardware store and bought new hose clamps all around but they are wider than the stock ones.
 
You can still get new boots from places like Boulevard Suzuki.

Please post up a picture how it is currently mounted with your issues though as I'm going through the same issue on my '81. I bought a new manifold to replace a busted part on my old one and my #1 boot (brand new on all 4 cylinders) isn't staying put. I'm interested to see if maybe it's because we're using the frame mounting point, as expected, under the seat.
 
Sadly, the airbox boots are not available. They used to be offered as part of the airbox assembly, that that part was discontinued some time ago.

I suggest installing the carbs to the airbox boots first, before slipping the carbs into the boots in front. Tighten up the band clamps good and tight and then shove the whole assembly together forward and stick the carbs into the forward boots. It will help if you heat up the airbox boots with a heat gun or hair drier first to soften the boots a little.

Good luck and hope this helps.
 
The air box on the 425 looks similar, could he buy those boots (13722-44010) ? Or the boots from a 750 (13728-45010), or would the air flow difference be too much?
 
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