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HELP !! 1985 GS700ES stock airbox install HELP !!!

  • Thread starter Thread starter Rkt-Rch
  • Start date Start date
R

Rkt-Rch

Guest
Ok so I found a stock airbox for my bike and went to install it... What the @#$@#@^%....

How in the :oops:%$#@*&&^&^:oops: do you get it in...

I took off the gas tank (check) I removed all four intake gaskets/mainfolds. and now i've tried to push,squeeze,etc... :oops: NO luck ! Break time.. any hints tricks or whatever someone can explain to this very frustrated person.
 
I've been told you have to drop the engine to do it... yeah, it kinda sucks.
 
air box.... pain

air box.... pain

are you serious !!! I kept looking at it and thats what I kept thinking but thought no that can't be, nobody in there Design right mind would make it that hard but I think your right.... $#%%$# it....
 
I have a 80 750L all you have to do is drop the carbs and it will slide rite in. When I was trying to put on pod filters I came across the same problem. I know you dont want to take the carb (like Me) but its the only way. PS dont drop the motor.
 
cbrophy22 said:
I have a 80 750L all you have to do is drop the carbs and it will slide rite in. When I was trying to put on pod filters I came across the same problem. I know you dont want to take the carb (like Me) but its the only way. PS dont drop the motor.
Click to expand...
Big difference in the two bikes
 
Putting in the stock airbox can be very tough, especially when you have about a 1/4" of clearance, and no more. I recommend using Vasoline
petroleum jelly, or lithium grease. It works very well and goes in very
smooth and easy.

Lubricate the O-rings on the intake manifiod "boots", and the O-rings on the air box and the intake side of the carbs where the air box mates.
Make sure you have both the throttle and choke cables already installed.

In time, it will become very easy for you after a few times taking the
box on and off. The lubricant really helps. I could not see you doing
it any other way. Vaseline has many great uses. It is a wonder lube
for very tight projects !!

:-D\\:D/
 
I've actually put the stock airbox back in - in less than 5-minutes.
It can be done if you work it and use enough lube as mentioned.
And it is easier to put it back on then it is to take it out.

:-D\\:D/
 
Really are you sure ....

Really are you sure ....

lube huh... i keep running into a clearance issue. I really dont want to drop the motor but again it looks like the only way.
 
I put that thing in before I rack the carbs...if the carbs are in there already pull them out and secure the air box first then squeeze the if your tryign to get them past already racked carbs you are really going to have a hell o fa time.. jus tpull the carbs and bolt the guy up then re-install the carbs...
 
81 550e
i found by disconnecting the battery box , it would move towards the rear wheel about 1" which gave a bit more room to fit the air box, rubbers, and carbs on the bike, worth a try eh
 
I've never heard of anyone having to drop a motor just to put in a stock
air box. This is absurd and unnecessary. It does not sound right especially
on a stock machine as yours is. I think you may be making this a complete hassle than it is made out to be.

The GS1100esd and your GS700es may be identical engineered machines. They the same, share the same wheels and swingarm, and the frame maybe a little different but the design is very close. I've taken this stock
airbox out many times, and again, with Vasoline or lithium grease, the
carbs easily comes right out, then the air box comes out. The box has to come out from the top of the frame. You may have to twist it out at
an angle - it will come out.

Smart Japanese motorcycle engineers would not design a bike where you cannot take the airbox out nor have t resort to jacking-up the frame
and to remove your engine just to take an airbox out. It is ridiculous !!

Reminds of my first car I had - a 1967 Mercury Couger hardtop. My first American car..........and my last. It had a 390 V8 engine in it. It was so poorly engineered, that I had to loosen the motor mounts, jack-up the motor JUST TO REPLACE MY SPARK PLUGS. Outragous, but this is the thinking and mindset of crap to the consumer. But these older Suzuki
GS bikes are well-engineered. They had you -the consumer- in mind
regarding this carbureter and airbox issues.

Just try to work on it a little longer with sweat equity and patience.
I would hate for you to remove your motor just to remove your air box,
as there is a solution for this.

:-D\\:D/
 
I'll give anybody $50 if they can remove and install a stock GS700 airbox without either pulling the engine, or cutting the box in half, installing it, then epoxying it back together.

It can't be done without doing one of the above. Even with all the carb boots removed.
 
jadesystem said:
The GS1100esd and your GS700es may be identical engineered machines. They the same, share the same wheels and swingarm, and the frame maybe a little different but the design is very close. I've taken this stock
airbox out many times, and again, with Vasoline or lithium grease, the
carbs easily comes right out, then the air box comes out. The box has to come out from the top of the frame. You may have to twist it out at
an angle - it will come out.
Click to expand...

They are completely different machines, with no common parts other than the front fairing and a few fasteners. Heck, the 700 is a monoshock and the 1100 is a twin shock. The airboxes look nothing alike, and fit into the frames differently.
 
Yes, and wow, I think you are correct. the GS700es is a mono-shock,
as I've only seen these rare bikes only on one occassion - here in the
bay area last month for only $400 !! Yes, only $400 and he still has it.

Very odd air box set-up you have. What a hassle you're in. It maybe
best to convert to individual air pods if this is going to be a future issue down the road. It does not make any sense for Suzuki to design such
an airbox where removing and servicing the carb is near impossible !!

What a compete hassle - I feel for you !! I would try to redesign it
so you can have easy access. Cut it, and make it accessable to slide
out. I cannot see what you are doing, but can imagine this as I write.
If my 1100 was designed like your bike, I would tear into it to make
it more maintenance-friendly as a plug and play.

:-D\\:D/
 
If you're intentions are to retain the airbox, then I would just cut it, remove it, and reengineer the box with a clip and fasteners with new insulation to seal the halves. Or just remove the motor if you feel this
is the only way out.

Man, what a hassle !! You're the first I've heard of with the airbox
removal issue !!
 
jadesystem said:
Yes, and wow, I think you are correct. the GS700es is a mono-shock,
as I've only seen these rare bikes only on one occassion - here in the
bay area last month for only $400 !! Yes, only $400 and he still has it.

Very odd air box set-up you have. What a hassle you're in. It maybe
best to convert to individual air pods if this is going to be a future issue down the road. It does not make any sense for Suzuki to design such
an airbox where removing and servicing the carb is near impossible !!

What a compete hassle - I feel for you !! I would try to redesign it
so you can have easy access. Cut it, and make it accessable to slide
out. I cannot see what you are doing, but can imagine this as I write.
If my 1100 was designed like your bike, I would tear into it to make
it more maintenance-friendly as a plug and play.

:-D\\:D/
Click to expand...
PM sent about the one for sale
 
I know a couple of people who said they carefully cut the front 1/3rd or so of the airbox off with a hacksaw or coping saw, then removed the box in two pieces to install their pods. That way, if you ever want to go back to stock, you reinstall it in two pieces, use some 30 minute epoxy to seal the crack, and wrap rubber bands or bungee cords around it to hold it together until the expoxy hardens. There isn't room to add any length to the airbox at all, because there is approximately 3/8ths of an inch clearance to get the carbs out between the airbox boots and the engine boots.

I've never done that cutting thing myself, I think I'll try it with my parts bike and see how well it works.
 
+1 to dropping the engine.


I could not figure out any way to get my airbox out without dropping the engine - it's literally that tight. Fortunately, I was pulling the engine anyways.


You'd think that Suzuki would have made a modular airbox instead.


-Q!
 
Way too much hassle just to access the carbs. Let me know how you attack this issue !! It will be interesting to see which route you take.

If you are going to keep the bike long term, you will be doing this again
in the future, then a modification makes sense. But if removing the
motor is not a big deal to you, and you have the time for it, then go
for it.

I personally don't like to remove a motor unless I'm rebuilding it, or absolutely have to. As that makes perfect sense to do so.

I'm going to get off this site as I'm too addicted in helping others.
I have a business trip tonite and must pack NOW.

Good luck to you, and let me know how things are going.

Ken
San Jose, CA
:-D\\:D/
 
Installing 1985 GS700ES Stock Airbox

Installing 1985 GS700ES Stock Airbox

It's in and just to say it was a pain... I/you must remove all the motor mount bolts and drop the motor, what a wicked stupid design !!

It's in and now that the carbs are out they to will definently get a quick clean and check over.

Cant wait to do this again NOT next time a box mod will be in order. Thanks for all the input now onto the carb running adjustment.... uggh.
 
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