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'81 gs650g air box/carb issues

  • Thread starter Thread starter Clint
  • Start date Start date
C

Clint

Guest
Hello,
I have just purchased an '81 GS650G. The previous owner messed with the carburators, and added pod filters. It runs flat at about 4000 rpm, and unless you ease into it after shifting it runs flat. I assume this is due an over lean mixture resulting from the pods (hopefully.) I went about gathering the original airbox and new Uni filter, before realising I don't have the frame piece the filter mounts to. Now I can't find that piece, after searching a salvage yard and ebay. Is there a way to tune the carbs for the pods, or should I try ordering an OEM box with all the pieces. I think it's about a 100.00 bucks, if it's even available.

The carb specs are:
Mikuni BS32SS
I.D.- 34200
BORE- 32MM
MAIN JET- #110
PILOT JET- #42.5
STARTER JET- #45

I would greatly appriciate any advice you might have.

Thanks,
Clint
 
It depends on if you have the stock exhaust or an aftermarket pipe. Have you worked on carbs before? If you have the stock pipe I would suggest going back to the OEM set up with a stock airbox and filter. If you do have an aftermarket pipe then you are probably better off going with the pods and re-jetting. The Dynajet kits are the ones most here prefer for a pods and pipe mod. I am no carb expert but see many posts of lots of trial and error when trying a pods and stock pipe mod or a stock airbox and pipe mod.
 
The stock exhaust system is still on, and no, I haven't really messed with carbs that much. I "cleaned" the carbs on my GT550, but it was a hack job at best. I want to get this GS in top shape for a summer tour with my girlfriend. Naturaly I want to do everything right on this one. She might get mean if we are stranded on the side of the road for lack of preperation on my part.:lol:
Do you agree the poor engine performance might be the pod installation?
 
You might be able to make a temporary frame for the air filter from a clothes hanger. I had a paper filter in an air box, someone does make one besides K&N.

Tell you what. I'll pull mine out and see if I can make a frame from a clothes hanger using the plastic one as a guide. It's supposed to rain this week so I won't be going outside to play anyway.
 
Wow, that would be great! I thought about trying something like that, but with no guide, I wasn't sure how to go about it.
 
Today 01:14 PM
Clint The stock exhaust system is still on, and no, I haven't really messed with carbs that much. I "cleaned" the carbs on my GT550, but it was a hack job at best. I want to get this GS in top shape for a summer tour with my girlfriend. Naturaly I want to do everything right on this one. She might get mean if we are stranded on the side of the road for lack of preperation on my part. Do you agree the poor engine performance might be the pod installation?
Click to expand...

Yes, with the stock pipe you are restricting the flow through the engine with the increased airflow of the pods. I think you are better off finding the OEM box parts you need and going back to the stock set up and jetting. That would also be the most reliable and easiest set up IMHO.
 
I feel that's the best way to go too. I don't think modifications are a good way to go with my limited mechanical expirience and budget.
 
Clint, I am sure BassCliff will be along shortly for your "official greeting". Check out his website, lots of good info on repairs, etc. If you are planning on doing some touring with the bike I would suggest you go through the wiring harness/headlight bucket and clean up ALL connections and grounds with contact cleaner and re-assemble with dielectric grease. After you do that run the tests on the stator papers. These motors are almost bulletproof and most issues are electrical IMO from not cleaning up the wiring harness properly and checking out your charging system.
 
Hey Clint...welcome. What kind of pods are they? Uni or the K&N ones. I have a 4 into1 pipe on my 650 and I have been thinking about going with the pods and getting rid of the stock air box? If you are going back to stock I might like to buy the pods off of you.
 
I don't know for sure, but I'm almost certain they would be a brand called emgo, based on what the seller told me. Pretty sure it was a cheap fix for the problem getting the part that is missing, rather than a performance mod. You are welcome to them free of charge.
 
I did a check on the charging system, and it puts out around 12volts at 4000 rpm. From what I gather this is a bit low, but my anolog meter may not be that accurate. Anyway, I plan on putting the Electro Sport replacement parts on. They don't have the regulator for the 650, but they have a "universal" suzuki one that might work.
 
hey Clint, that is damm nice of you!!thanks, but if I go that route they need to be K&N so they would also match the color scheme of my bike. The dark red of the K&N ones is like a perfect match.:D I might have to start thinking about the dyno jet kit and some pods.

Let me know if need any help anything on your bike, I also have some spare parts but not the filter cone you need.....unless I ending up going to pods...then I would have a complete airbox assembly with a brand new UNI filter.
 
That is a nice looking bike you have Bri. The K&Ns would deffinately be a cherry on top, if you decide to go that route. I have them on my Guzzi and am very happy with them.
 
Thanks Clint!, I just rebuilt it last spring/summer. I like the look of the K&N pods and if I get some more power out of it...yay. I am just concerned with the tuning of the carbs. Not a big fan of trial and error.
When I built my V65 Magna it was a total pain..carbs on and off too many times, make a jet adjustment only to find I didnt go big enough, then jumped 2 sizes only to find I went too big. The slow jets at least I got lucky with them being just 1 size up.
 
Clint said:
I did a check on the charging system, and it puts out around 12volts at 4000 rpm. From what I gather this is a bit low, but my anolog meter may not be that accurate. Anyway, I plan on putting the Electro Sport replacement parts on. They don't have the regulator for the 650, but they have a "universal" suzuki one that might work.
Click to expand...
I offer Honda RR kits for 40.00 that are quite popular around here. Guaranteed to work on your 650G.
Tomorrow I will see about how to make a cage for that air filter. Sometimes people spray start fluid in there and it distorts and destroys the plastic cage.
 
Nice bike... love it!!!!

Nice bike... love it!!!!

hey Bri... I really like what you have done with your 650.... she is lovely.
Makes me jealous... I want mine to be just as clean.... but I've only had it for a couple of weeks... so I must be patient.
One question for you... what did you use to paint/cover the engine parts? that black looks nice (I am talking about the crank case cover, etc...)
Thanks for the information-
 
Clint, Duane has the best deal with his regulator/rectifier.

For your 650G, try to return it to stock if you can. When properly tuned, the throttle acts like a rheostat on an electric motor with that model. No flat spots at any RPM in any gear. Plenty of power, low gas consumption.

Later, if you want more, you can go back to pods if the stock situation isn't enough, and you have the time to put into it.
 
Hey Julien, thanks!! I had owned it for a long time before I decided it deserved to be gone thru.The main thing was just to get the motor out and fix my second gear issue. Then I came down with a bad case of "while i'm in there". It totally snowballed into this major thing.
The motor cases,covers,cyl,and head, I powdercoated all that stuff wrinkle black. The detail parts of the motor(oil filter cover, valve cover end caps, breather cover, and starter cover) I did in black chrome powdercoat.

Hey Clint, I agree....get a honda RR from duaneage. You wont regret it. I have a honda RR on my bike and it works great.
 
When I make this cage I'll take pictures of what I come up with, this might be useful for more than a few folks. One of the 650Gs I parted out had a malformed plastic cage for the foam filter caused by too much starter fluid.
The 650G is a very well tuned machine with stock parts. The only stumble I ever found on the three I have ridden was a slight twitch at 2200 rpm when the mid speed circuit kicks in. Properly synchronized and clean these babies purr. The power is very smooth and uniform without a sudden rush or hesitation.
Considering how nice they run with an airbox I can't see a great reason to go pod on these, any horsepower increase would be small and gas mileage no doubt would be less because of the rejet required.

I understand the 650G was factory jetted a tad lean for emissions. Going up a single size on the mains is supposed to improve them a bit. I haven't tried it, I'm happy with the way it runs now.
 
Thanks for all the great advice! My project is sure to succeed with all your help. I will get started with my carb project as soon as I gather the parts I need. The charging/electrical system is a top priority as well. I'll keep you posted:)
 
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