Confused on how to install the airbox on a 1982 GS450L.

[lettuceman44]

So I have the airbox inside the frame, but I'm confused as to the rest of the installation.

1. it came with two hoses. I know one connects at the top to the engine. The other hose has what looks to be a cap on it. No idea what to do with it. Looking at schematics, it looks like it's a drain tube, but schematics show the drain tube coming straight down. This tube is L shaped.

2. What are the two circle openings at the back of the air filter?

3. Does the air filter get mounted to the frame in any way? At the top, there are two screw holes, but I don't see anything that would screw in it.

 

[Rensdw]

From what I remember when my GS450E was stll original:
1: The first hose you mention is the air breather hose that goes from the front top of the airbox to the valve cover, the second hose is just a drain tube that is connected to the bottom of the airbox en just goes straight down is not connected to anything.
3: The two circle openings are the connections to your carburetors, the should be rubber velocity stacks in there that are mounted in the airbox by a recess in the rubber and to the carburetors using a clamp.
3: There are plates that you can screw to the frame on both the left and right side that hold all the electronics, relays, CDI etc. etc. and they also have bolt holes for the airbox.

Look up some exploded views it will give you a clear view of how everything is put together.

 

[lettuceman44]

1. For the drain tube, I don't know which nozzle to attach it to. There are two. One that points straight down, and one that points straight back. The drain tube I have is L shaped, so it seems to connect to the one that points straight back, but I don't see that in schematics anywhere.

2. I'm meant the other side, not the side that connects to the carbs. There are two small holes there.

3. I have the plates, but I don't see how they allow the airbox to attach to it. The plates are attached to the sides of the bike. The airbox has holes on top of it.

I've been trying to find a nice exploded view, but I can't find anything except for what I found on bikebandit for the airbox.

 

[lettuceman44]

It seems the PO might have removed the airbox mounting points. ****ing hell, why?!?

Can someone show me a picture of what it is supposed to look like?

 

[Rensdw]

Go to CMSNL.nl and search for "GS450L" the 1983 USA version should be the first the pop up, there you can find exploded views of anything.

 

[Guest]

Check out this link:
http://www.suzukipartshouse.com/oemparts/a/suz/50d3f23bf8700230d8b4bdaa/air-cleaner

Cheers!
K

 

[lettuceman44]

Thanks guys, gonna take a look now.

After taking a look, that is the view I was looking at before (just not on Suzukipartshouse). Like I said, it shows a tube coming straight down. Mine is L shaped though, and seems to fit on another nozzle near the back that is parallel with the ground. L shaped tube makes it so it points straight down. What is that for?

Also, no mounting hardware in those diagrams. There is nothing on my bike it looks like it can mount to, so it probably got removed. I'll have to fabricate something new.

 

[lettuceman44]

Go to CMSNL.nl and search for "GS450L" the 1983 USA version should be the first the pop up, there you can find exploded views of anything.

This site doesn't seem to exist.

 

[Gorminrider]

This site doesn't seem to exist.

here, but it's the same
http://www.cmsnl.com/suzuki-gs450l-1982-z-usa-e03_model34212/partslist/

have a look at the frame on the parts fiche too. That piece of metal floating above is a piece of your puzzle, I think...the regulator and solenoid attach to it but it also connects to airbox...I don't have an L specifically someone with one might post pix for you...

 

[lettuceman44]

Thanks, I'm looking but I can't visualize what it's supposed to look like.

Hopefully someone shows me how their 450 airbox is mounted.

 

[Guest]

I just looked at the air cleaner for a 1983 GS450L and there is an l-shaped tube as you describe. Not sure if this will help at all, but here's the link just in case:

http://www.suzukipartshouse.com/oemparts/a/suz/50d3f24af8700230d8b4bde5/air-cleaner

Cheers!
K

 

[potato potato]

I am in the process of tearing down a 1982 450L. I have attached a pic that should help show what tabs, if any, you are missing for mounting.

Also, let me know if you need any pics of my airbox. I only had two tubes, one breather and one straight drain.

 

[GSXR7ED]

Pics Included

Pics Included

So I have the airbox inside the frame, but I'm confused as to the rest of the installation.


1. it came with two hoses. I know one connects at the top to the engine. The other hose has what looks to be a cap on it. No idea what to do with it. Looking at schematics, it looks like it's a drain tube, but schematics show the drain tube coming straight down. This tube is L shaped.

Based on this suzuki parts schematic (#11), the "L" shaped drain tube is directed to the side as opposed to downward like on my "T". I would imagine there would be a support clip/ring to keep it in place.

2. What are the two circle openings at the back of the air filter?

There are two areas you could be talking about. The back of the air filter are #9 & #10 on the above diagram. It's for the metal cap that covers the air filter. Unless you're talking about the front where the air vents are located. If that's the area you're talking about, it looks like the holes are intended to be mounted on a cross bar that you may not have on your bike.

3. Does the air filter get mounted to the frame in any way? At the top, there are two screw holes, but I don't see anything that would screw in it.

Yes, the air box assembly should be mounted onto the frame of the bike. Take a look at the frame pic provided by potato-potato and let us know if you are missing that cross-bar.



Ed

EDIT: Single front disk, snowflake rims and rear brake shoes.

 

[lettuceman44]

I do indeed seem to be missing that crossbar.

Thanks everyone for the help.

 

[lettuceman44]

I just looked at the air cleaner for a 1983 GS450L and there is an l-shaped tube as you describe. Not sure if this will help at all, but here's the link just in case:

http://www.suzukipartshouse.com/oemparts/a/suz/50d3f24af8700230d8b4bde5/air-cleaner

Cheers!
K

Ah, duh. Should have checked other years.

That explains it, I have a 1983 airbox. Gotcha.

 

[lettuceman44]

Ok, so now that I fixed other issues I can come back to this.

I'm looking at the pictures of the frame you guys provided, and I do not see where the airbox would be screwed in. I'm so confused now. It looks like there is nothing there at the top that has actual screw holes.

 

[Gorminrider]

Do you see those welded-on tabs in the picture above? in the "triangle" of the frame? Those have rubber grommets (similar to the side cover ones) but with bushings inserted. ...You recall I mentioned the piece "floating above" in the fiche? anyways, Screw/bolts go through that "floating plate", through the frame mounted tabs with bushings and then into threads of the airbox..can't recall if there's nuts molded into the airbox but it's definitely metal you screw into....the plate now attached is holding the airbox and provides a place to bolt on the solenoid and regulator... That's the left side.
Next, the metal battery box performs the same function on the right side ..screw/bolts go through it, through the frame welded tabs with bushings and into the airbox nuts.
So I recall it, anyways without taking it apart.



You may yet need another picture but I can't do it just now. One thing for sure, you are not going to MOUNT the airbox until the carbs are in place on the engine intakes....except as practise.

 

[lettuceman44]

Are you talking about the tabs in the side?

I'm looking at your picture and I don't see any tabs facing vertically. Just horizontally in that triangle section of the frame.

The airbox has the screw holes on top.

And I just found out why......the airbox I have is from a 1983 -_-

It's different from a 1982. Damn.....

 

[Gorminrider]

I'm looking at potato-potato's picture upthread....(as an irrelevancy here, It actually looks like a 400E frame to ME because those bent metal tabs are what I have on my Canadian GSX 400E for the sidecovers at the top. There is also, somewhere, a very similar tab with a different rubber doughnut that is for the sidecover's bottom- but anyways....) yes, the tab on the side and top are indeed the ones I was describing in the expectation that yours was similar. Still, the method using rubber mounts for the airbox may still be the same wherever they are....

82-> 83? indeed a b*gger maybe...But unless you can somewhere get the correct airbox, perhaps you can still use this wrong one? Main thing is it matches up with your carbs and that it doesn't interfere with other things...you could bend a strap right round the frame, drill holes to take some homemade rubber washers and inserted bushings to screw through into the airbox

OR use the mounts existing on your bike, and drill holes in the "wrong" airbox to take the bolts and nuts and washers you can put inside the airbox.

You are not alone in your confusion-Suzuki DNA is complicated...and bikes have a very narrow supply of possible donors especially for body-bits.

.

 

[lettuceman44]

The airbox is all lined up and connected to the carbs, so it's completely functional, just doesn't have the mounting options. Mystery solved though haha.

Yea I'll have to think of a way to get it screwed into the frame