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    #1

    GS1100 Airbox Boots

    '82 GS1100EZ. I bought some new airbox boots and rings and am wondering if any of you have any tips on removal of the old ones and the installation of the new ones. I don't want to mangle anything, so I figure if anybody's done it before perhaps they can save me some blood, sweat, and tears. Thank you!
    Kevin
    E-Bay: gsmcyclenut
    "Communism doesn't work because people like to own stuff." Frank Zappa

    1978 GS750(x2 "projects"), 1983 GS1100ED (slowly becoming a parts bike), 1982 GS1100EZ,
    Now joined the 21st century, 2013 Yamaha XTZ1200 Super Tenere.
    Tags: None
    #2
    Do not have any advice on getting out, but I would not use heat, do not warp the airbox, because of the holes and small area of plastic between them they are week and easily warped with heat.
    Try some Vaseline or a light greasing to slide in.
    Had never done the rings on a GS but on my Seca with the new rubber they went in easy.
    Did not understand that I needed new rubber and that the boots had shrunk to much for the rings to go in well.
    Wish I had known about Motorcycle forums back then!

    Comment

      #3
      That is one serious wrestling match there. I used a little silicone lube on mine and just kept going around the ring pushing it a little at a time with the edge of a punch. Youll knock one out a dozen + times for every one you get it, they are a PIA. Id be very happy to never put another set in.

      Comment

        #4
        Originally posted by Katarat View Post
        That is one serious wrestling match there. I used a little silicone lube on mine and just kept going around the ring pushing it a little at a time with the edge of a punch. Youll knock one out a dozen + times for every one you get it, they are a PIA. Id be very happy to never put another set in.
        What rings are you talking about? The clamps or the rings that go inside the boot to the air box. If those are the ones, use the split ones that come with the bike, the new solid rings are dang near impossible to get in. I tried everything I knew to try on my bike, went back with the older rings, everything was fine.
        sigpicMrBill Been a GSR member on and off since April 2002
        1980 GS 750E Bought new in Feb of 1980
        2015 CAN AM RTS


        Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

        Comment

          #5
          I took tin snips and cut small slits all around the boots about and 1/2 inch a part and back as close to the rings as I could. Then pushed open the out outside of the boots then lubed and slowly pryed them out working a little bit at a time around them,Then pushed the boots inside the air box ,collapsed them in and removed them, Reinstalled the new boots and lubed them and reinstalled the rings again slowly working around them a little bit at a time *noteing the small lip the rings have on them* which faces out, until they were seated back into place, No damages to nothing and looks totally stock. Took about 1hr.though,and a lotta patience. PIA is another good description also.
          Last edited by gs11ezrydr; 11-22-2013, 07:03 AM.
          sigpic 82 gs1100ez 1168 Wiseco,Web .348 Cams,Falicon Sprockets,Star Racing Ported Head,1mm o/s Stainless Valves,APE Springs,Bronze Guides,etc.APE Billet Tensioner,36CV Carbs,Stage 3 Dynojet,Plenum w/K&N filter,Trued,Welded,Balanced,Crank w/Katana rods & Billet left end, FBG backcut trans, VHR HD Clutch basket,APE nut,VHR High volume oil pump gears,1150 Oil cooler,V&H Megaphone header w/Competition baffle,Dyna S,Coils,Wires,etc.Other misc.mods.

          Comment

            #6
            I got everything out no problem, but had to sacrifice the rings, which by the way were solid rings. I pretty much figured I was going to have to do that so I had ordered new ones anyways. Everything came out quickly and easily that way. One thing I DID notice once everything was out was the centre boots had "center" molded into them, with the part number 13882-49300 on them as well as 13881-49020. The outside ones had only 13881-49020, as did the new ones. The number on the package of the new ones is 13881-49021. According to the parts picture, they are all the same, part #13881-49020, with no special ones for the centre. The center ones are also a hair longer. The section that between the ring groove and where the edge of the carb stops is visibly wider. What gives?
            Kevin
            E-Bay: gsmcyclenut
            "Communism doesn't work because people like to own stuff." Frank Zappa

            1978 GS750(x2 "projects"), 1983 GS1100ED (slowly becoming a parts bike), 1982 GS1100EZ,
            Now joined the 21st century, 2013 Yamaha XTZ1200 Super Tenere.

            Comment

              #7
              I finally got them installed, I was in no huge rush, so they got done when they got done. I got three of them in just by lubing them up with silicone lube and pushing them in with my thumbs, (OWW!!). I tapped them home with a hammer and flat nosed punch. The last one was a "female dog". After much farting around an even taking it down to my friend's MC shop, we finally got it in by soaking the rubber in hot water and then lubing the ring up and pushing it home with a large socket. Thank you all for your suggestions.
              Kevin
              E-Bay: gsmcyclenut
              "Communism doesn't work because people like to own stuff." Frank Zappa

              1978 GS750(x2 "projects"), 1983 GS1100ED (slowly becoming a parts bike), 1982 GS1100EZ,
              Now joined the 21st century, 2013 Yamaha XTZ1200 Super Tenere.

              Comment

                #8
                My Katana had pods on it so I didn't have the original split sleeves and I was putting it back to original. Glad you got it. The more you do the easier it gets. Warming up the boots in warm water helps too, forgot to mention that, it was a few years back

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