81 GS650G air intake removal

[Guest]

Try as I might (new plugs / carbs drained / fresh gas / new battery) my 81 650G won't fire. Spark is good (have tested all 4) but she just won't fire. Just turns over. There's a slight amount of fuel (after cranking it for 30 seconds) in the air breather (filter) but I'm of the mind that my carbs must be gunked up.

Question is...how do I get the intake unit off? It's the large, black plastic unit. I see the 850 has 2 bolts on the top but mine has none. Otherwise, getting the carbs out seems like a nightmare.

Any other possible work-arounds?

many thanks

[BigD_83]

That intake is secured to the filter box, which in turn is held by one bolt on each of the left and right frame.

Typing in my phone so I hope that makes sense



That's just the start. The joys of hard carb boots make removal an arduous procedure involving plenty of choice words, scraped knuckles, and repeated questioning of necessity of their removal.

Sometimes removing the air filter box and bolts will allow one to push the filter box back just far enough to get the air plenum off.

[Redman]

That airbox on the 650 is different than all other GSes. (there are a few things unique to the 650s).

SO when folks here give advise, will need to determine if there expereince is specific to the 650.

I dont recall the specifics of the 650 I had (82 thru 2005?6?) because I didnt have to work on it much. So I cant help you, other than to say some things are different that all other GS, and the airbox is one of them.

[tom203]

"Try as I might (new plugs / carbs drained / fresh gas / new battery) my 81 650G won't fire. "

Sadly this stuff won't help much until the carbs are properly cleaned. Removal is no fun...you need to slide airbox and airfilter box back so airbox pops out of carbs mouths. 1/2 inch is a big deal here so relocate stuff that prevents airfilter box from rearward motion. Take pics to aid in reinstalling stuff later.

[Cashmad]

thanks folks. Yes, the 650G has a very unique air filter setup and it's hideous (in appearance and location).

I'll try the above advice and will report back. The beauty is so close....I can feel it.

[Redman]

What IS commom to all other GSes is that carb cleaning needs to be more than just spraying around some carb cleaner.
Carbs need to be completly broke down, and each dipped in carb dip solution for 24 hours, ..... see the carb cleaning series, back on the homepage of the website (not the forum, the website).

[Steve]

The only 650 I have had the "pleasure" of working on had pods, not a stock air filter, so I don't have direct experience.
However, there is one other tip that works on the 550, might help on the 650, too.

The front half of the rear fender is plastic and snaps into grommets in the frame, much like the side covers. Pop those fasteners loose, slide the fender back. It will only go about 1/2", but that might be what you need to get the air filter housing to slide back far enough to move the air plenum out of the way.

When you are done, don't forget to snap the fender back in place.

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[Mr.humbucker]

I have just finished up putting my GS650G 82 back together and it appears to have the same configuration as the 81 for the air box and intake air box. As per the link below bolts 14 and 16 as well as two the large band number 10 when loosened will free up the air intake plenum. Once this is done it should move back quite easy. There maybe two more bolts on the bottom of the airbox. They aren't shown in the illustration but they're in the two slots you see near the number 11. Popping the carbs off the manifolds into the engine take a bit of work. I often use a wooden handle of a hammer to help leverage them off.

https://www.partzilla.com/catalog/suzuki/motorcycle/1982/gs650g/air-cleaner

A proper cleaning of the carbs with a near full disassembly is the way to go. A bit of a learning curve but there's a ton of videos and documents here and on YouTube.

[Rob S.]

I had a similar problem with my 11E. I used a special tool. It's called a dremel.

[Steve]

When someone asks to borrow my Dremel, I hand them my engraving tool. It's a Dremel.


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