Getting ready to have carbs rebuilt

[JTGS850GL]

Ok, today's job was to get the carbs removed for a rebuild and identify any issues from the PO. Issues there were... Looks like I'll have to source some parts:

There were two damaged intake boots. I'm assuming that these can not be repaired and are not usable, so I may be in the market for one Left and one Right intake boot for a 1980-1983 GS850. The other two were in good shape and still fairly soft.




When I got to the air filter I found this:


No idea what the PO was thinking here. Looks like he used home air filter material and tried to hot melt glue it to the housing. I plan on replacing with a K&N filter but open to other suggestions. Don't want to go pods though.

Also found one of the airbox outlets a little buggered up:


Can't seem to get that metal band seated right. Any suggestions?

Of course the intake O-rings were shot:


They looked more like plastic shims then O-rings.

Found several band clamps that needed to be fixed or replaced as well

[tom203]

Don't mess around- get four new boots and know they are all good!

[mrbill5491]

Ditto, get all new rubber boots fore and aft and O-rings. As for the metal rings, when you get the new air box boots, they will probably come with a solid ring, mine did. No matter what I tried or used, I could never get those new rings on, I just used my old split rings, just pull them a part just a bit, they install much easier. Replace the boot clamps as well, they aren't worth repairing, once they are boogered up like yours they never seal up right. The air filter, K&N is fine. Been running one since 1982.

Inspect the air box and make sure there are no cracks and such. You want all this to seal up tightly.

[JTGS850GL]

Looky what I just picked up:


I always wanted a mercury sync tool and found one NOS unused for under $50 delivered. Hate the Motion Pro blue liquid tool I have now. I know how everyone loves the Morgan Carbtune but I'm old school and still love the simplicity and repeatability of liquid silver.

[850 Combat]

If you don't want to tackle the carbs yourself, there are a couple fellows on this list who will a good job for a reasonable price.

Chef3166 did my last set that were too difficult for ne to dismantle without breaking. He did a great job. The Café Kid does them too, and his reviews are positive. I wouldn't take them to a shop or buy a rebuild kit.

You can use weatherstripping between the filter housing and the airbox, and where the chrome covers meet the airbox.

[JTGS850GL]

I decided to send them to Chef3316 a couple of weeks ago. Not so much that I'm intimidated with doing the rebuild (have done a number of Mikunis over the years), as much as an issue with time. I own my own business and have little time left after a day of work. The money is tight, but I still feel the money will be well spent. I have no history on these carbs and feel a well versed set of eyes would be of benefit. I'll be sending the carbs with a complete set of O-rings and float bowl gaskets out to him tomorrow. Good to hear that I made a good choice on who to send them to.

Already did the weather stripping at key points and ordered a K&N SU-1200 filter. The bike was running lean at part throttle but I feel that the main causes are being addressed. The bike does have a V&H 4into1 exhaust but I think the main issues were a lack of air filter, old intake O-rings, distorted/loose clamps and damaged intake boots. While the carbs are out for a good cleaning I'll be getting the valve tolerances all fixed up. Everything is here (valve cover, vent cover gaskets, new half moons and shim tool. I just need the time to get started and identify what shims I need. Once the carbs get back it will be on to adjusting the pilot screws and balancing the carbs.

It's been 20 years since I've worked on bikes, but it's all coming back to me.. The last time I owned a GS it was a 1979 GS1000L that was purchased new. I find it ironic that the first bike I get after a 20 year hiatus is a GS of the same era.