stubborn carb reinstall...

[ninjadave7]

I know this is an amateur question, but I just took the carbs off my '80 GS850 and did a thorough rebuild and now I can't get them back on for the life of me. I tried dish soap, maybe I need more? I put the bottom half in and tried to get the top but it was always one side or another. The little metal stub that's part of the engine keeps getting in the way, and I'm ready to give up... ha.

any help???

[Steve]

"Little metal stub that's part of the engine"???

Sorry you are having problems. The 850 is probably the EASIEST GS to remove/install the carbs.

If it weren't for having to play with the throttle and "choke" cables, you could just about stand back and throw them into place.

.

[terrylee]

Not sure what you mean by metal stub? Perhaps the cam chain tensinor below carbs? Are the boots to the engine still fairly soft or hard? If hard you'll need ones that aren't. Try some light amount of some w-d 40 or similar lube around the inside edge of the boots. Take your time and try to line them all up at same time and sometimes if you can tap them with your hand from behind they should pop on. terrylee

[Griffin]

Use a hair dryer for ten minutes or so on the carb boots to warm them up and make them more pliable.

Spray them with silicone spray too.

[ninjadave7]

sorry, I probably did mean the cam chain tensioner, because it has knob on it. I just didn't know what it did. the boots were replaced a couple years ago, but they're definitely not hard. i had an easy time before I rebuilt the carbs, wondering if they aren't aligned or something. I'll try the wd-40.

[JEEPRUSTY]

Is there any chance you re-ganged the carbs in the wrong order?

[spyug]

Take a deep breath......become calm.

Now if the boots are old they are hard and that doesn't help. I use an electic paint stripper gun (looks like a hairdrier but more powerful) to heat them up. Put the heat to them but don't let them burst into flame. When soft again squirt the mouths with silicone lube or WD40 or your favourite lube.

The trick is to get the four carbs into the mouth of their respective boots then apply equal pressure to carb 1 and 4 to pop them in. To do this I find bar clamps to be the easiest, the type with the ratchet hand clamp.Clamp the front of the head and carb(one clamp on the left and right side)and squeeze them in.

If you don't have bar clamps you can also use a ratchet strap i.e. a ratcheting tie down strap. Place a piece of 2 x4 (or perhaps something thinner) the width of the rack of carbs on the intake side and wrap the strap around this and the front of the head. Use the ratchet to draw them in.

You can also lever them in using two pry bars or long screw drivers but you will need an assistant to work one bar. Place the tip of the bar or screw driver against the rear motor mount and with a piece of wood against the mouth of the carb push the bars forward popping them in.

Before putting the carbs back in its easiest to attach the cables I'm sure you'll find.

I hope that helps a little bit.

Good luck with it and let us know how it goes.

Cheers,
spyug

[ninjadave7]

I suppose I might have, but I was pretty careful, and every part fits perfectly. I don't know what other order they could go in, but never hurts to check I guess...

[Mop Bucket]

Take a deep breath......become calm.

Now if the boots are old they are hard and that doesn't help. I use an electic paint stripper gun (looks like a hairdrier but more powerful) to heat them up. Put the heat to them but don't let them burst into flame. When soft again squirt the mouths with silicone lube or WD40 or your favourite lube.

The trick is to get the four carbs into the mouth of their respective boots then apply equal pressure to carb 1 and 4 to pop them in. To do this I find bar clamps to be the easiest, the type with the ratchet hand clamp.Clamp the front of the head and carb(one clamp on the left and right side)and squeeze them in.

If you don't have bar clamps you can also use a ratchet strap i.e. a ratcheting tie down strap. Place a piece of 2 x4 (or perhaps something thinner) the width of the rack of carbs on the intake side and wrap the strap around this and the front of the head. Use the ratchet to draw them in.

You can also lever them in using two pry bars or long screw drivers but you will need an assistant to work one bar. Place the tip of the bar or screw driver against the rear motor mount and with a piece of wood against the mouth of the carb push the bars forward popping them in.

Before putting the carbs back in its easiest to attach the cables I'm sure you'll find.

I hope that helps a little bit.

Good luck with it and let us know how it goes.

Cheers,
spyug

Had the same problem putting my carbs back in. Such a big problem I have been putting off taking them off because I dread putting them back again. I did use a bunch of silicone lube on the boots and that seemed to help. Spyug's advice makes me want to pull the carbs if there is hope to get the carbs back on with out breaking my back.

[ninjadave7]

I'll give it a shot in the morning. I have an assistant, some long screwdrivers, a 2x4, some clamps, some wd-40, I will prevail!

[Katarat]

I straddle the bike and push them in that way so you can get equal push on the carbs on my 1100E & Katana 1100. Try sticking the carbs in with them down in the rear then pushing up & in on them. They can be a bear but this works best for me. For got to mention some electrical silicone on the boots too

[Souske]

I used a bit of atf to lube the boots, thenplace the bottom lips of the carb mouth in the boots, and then pivot them up and in