Removing carb-to-engine intake flanges...

[TitanNeil]

Replacing the intake o-rings? It is a bugger to remove the inner 2 boots with an impact driver, as you have no place to swing the hammer - so find a 2' piece of heavy pipe about the same diameter as your impact and duct tape it onto the end. You can then poke it through the frame near the battery box and whack on the end of the pipe instead of the driver itself.
Basically, you're making a 2 1/2' long impact driver.
I did this, it worked like a charm! Just as easy now to remove the inner as the outer boots. Replace the screws with Allen-head cap screws (put a dab of antiseize on them) and you're done.

 

[tkent02]

You can also use a few 1/2" socket extensions on the impact.

 

[Don-lo]

Your idea is interesting. Hmmmm, duct tape, Canada, ...., is there a connection?

I use the cascade theory for intake boot removal. I use the impact (or 5" vicegrips) to remove the outermost bolt, then unscrew the other bolt while tapping the boot itself counterclockwise. With that boot out of the way, you can get the the 5" vicegrips on the next exposed bolt, and repeat the unscrewing/tapping process for the second bolt. Go over to the other side of the bike and repeat for the other 2 boots.

Then, reinstall with allen head bolts and anti-sieze.

 

[sam78gs750]

I wish I woulda thought of this 3 months ago when I replaced my intake boots! would've saved me a bit of welding of nuts onto those inside screws... Great tip!

 

[ddaniels]

Amazingly, mine came loose with just a large phillips head screwdriver. I was so pleasantly surprised.

 

[woodman]

Take the bolts out of the battery box and the carbs will come right off, easy access

 

[Nessism]

I spin the boot after vice gripping the outer screws out. 1/2" extensions on the impact driver work too as Tom suggests.

 

[bmac]

screw removal

screw removal

What I have found to work well in those tight area's is using a 1/4 inch ratchet with a small extension, use a 1/4 inch socket install a phillips tip into the socket and tap lightly on the combo with a hammer and ratchet it out. P.O.C Bob

 

[Guest]

Just pull the motor

 

[Keith H]

I just did the intake o-rings on my 82 GS650. I used a cordless electric impact tool and they popped right out. (I use the tool to loosen almost everything on my bike----hasn't failed me yet!) Sears has 'em....I'm sure you can also find them at most any good tool department.