Help my air box will not seat properly!!!

[Guest]

Hello all new to the forum had my gs 1000 running real good after taking all you're advice. Then the dreaded head gasket blew so stripped it down checked everything new base gasket new head gasket oil seals evrything my problem is getting air box to seat on the carbs properly tried every which way but no joy I know it's probably the most posted ever but I could not find please help losing will to live 1979 gs1000 thanks in advance great site never had to ask before just read and followed you're advice. Caveman Dave ride free

[Nessism]

Clamping off the airbox boots to the carbs before inserting the carbs into the boots on the head sometimes helps. The clamps tend to stretch so some new ones may help if the boots want to slip off the carbs. The real problem is the airbox boots shrink and get hard with age. Unfortunately, these parts are not sold by Suzuki. You can get the boots from the GS750 and try them instead though... Part# 13728-45010 Desc HOSE AIR CLEANER. There have been some older threads (now in the archives) where people have reported success using these parts.

Good luck and don't forget to use that period key now and again.

[rudeman]

Good luck and don't forget to use that period key now and again.

Hahahaha!

Seriously, I had difficulty when the airbox would collapse in the #2/3 carb area. I removed the rear box (air cleaner) and using a tire iron inserted into the plenum, I applied some pressure to that area until the boots were properly seated. I then clamped those two and proceeded to fit the remaining boots.

Dumb question but did you leave the forward box unattached from the frame mount? Just asking to make sure...

[Caveman Dave]

Thanks guys great advice as usual. Still not sorted though also sorry for posting in wrong forum same with period key newbie. Learning by mistakes lol

[chuck hahn]

Steve and ED sort of hit it on the head. What I have found is that the engine heat .over time..allows the plastic to soften and eventually it starts to get sucked into itself from the air draw when the engine is running. Much like you sucking the air out of a soda bottle and it collapses into itself.

What you need to do is slowly heat the face of the airbox and use something from the rear to push the face back out flat again and hold it there till the plastic cools and it stays again.

This make 2 things happen..the boots will again be far enough forward. The boots will NOT be getting STRETCHED forward to make fit and be overly strained subjecting them to possibly tearing or otherwise becoming damaged.

[mrbill5491]

Hahahaha!

Seriously, I had difficulty when the airbox would collapse in the #2/3 carb area. I removed the rear box (air cleaner) and using a tire iron inserted into the plenum, I applied some pressure to that area until the boots were properly seated. I then clamped those two and proceeded to fit the remaining boots.

Dumb question but did you leave the forward box unattached from the frame mount? Just asking to make sure...

Yes, you need the wiggle room to mount the carbs to the the head boots. Once those are in, just screw in the mounting bolts but loosely until you have the front boots seated properly and tighten down. Then go back tighten the mounting bolts and inspect all the boots to make sure they all stayed seated, then reinstall the filter box. Seems like the #2 is always the pain for some reason.