GS550e with CV carbs - stuck inlet manifold screws

[ajh]

Hi

Need to change the inner inlet manifold and the screws are stuck solid. I dont want to chew up the head just yet so have tried knocking the edge of the screw head with a flat driver to try to turn it with out success.
I've removed carbs and I think the best solution would be an impact driver but there is not enough room to get a normal impact driver in and hit it. And Im not sure I could even get my drill in as a last resort to drill the head off

Im sure this is a common problem so anybody recommend a type of impact driver that will fit/work? Or an alternative idea?

Also, could anybody recommend after market inlet manifolds? (Im not paying the ridiculous Suzuki prices )

Thanks

[Nessism]

Grab the side of the screw with some vice grips and crack it loose. Once the outside screw is out you can try spinning the boot CCW to see if the screw comes along for the ride (it often does.)

[phydeauxmutt]

Most impact drivers have a removable head. What is under there is likely a 3/8" square drive, so just get a couple of extensions so the body of the driver is over the airbox and battery area, giving you plenty of room to give it a good smack.

Be sure to use the proper bit. It's actually going to be a JIS screw, but a #3 Phillips bit in the driver will work just fine. Be sure to toss those junk screws away when you get them out. Replacements are available from cycleorings.com, where you can also find replacement o-rings, if your new manifolds don't come with them.

[ajh]

thanks both,
Ive tried doing the outer screw first with the idea I might be able ot turn the manifold but I think even the outer is too tight for grips so I didnt try as I havent got the manifold yet. I siliconed the manifold and put everything back and it seems to be holding for now but once I get the manifolds I can give it a go
Good to know that with extensions you can get them past the airbox and hit it. I've got JIS screwdrivers but think I'll invest in a JIS impact bit before I do this.

I'll report back to complete the thread when I do it
Cheers

[ajh]

Has anyone experience of using Chinese inlet manifolds? They look right other than sh1tty hose clips but is quality ok?

[Grimly]

Has anyone experience of using Chinese inlet manifolds? They look right other than sh1tty hose clips but is quality ok?

I bought a cheap set for my XJ and gave them a good inspection. They didn't fall apart, but I've yet to fit them.
Others who bought some of the cheap ones have been happy with them for many miles but some other ones have fallen apart (bad bonding to the flange, vac inserts falling out, etc), but that's happened within a few thousand miles of use.
I'll probably fit these and see how they go. It's a crap shoot.
I'd have been happier if mine had been available from cruzinimage, as he normally stands by his stuff.

[metalfab]

Hi

Need to change the inner inlet manifold and the screws are stuck solid. I dont want to chew up the head just yet so have tried knocking the edge of the screw head with a flat driver to try to turn it with out success.
I've removed carbs and I think the best solution would be an impact driver but there is not enough room to get a normal impact driver in and hit it. And Im not sure I could even get my drill in as a last resort to drill the head off

Im sure this is a common problem so anybody recommend a type of impact driver that will fit/work? Or an alternative idea?

Also, could anybody recommend after market inlet manifolds? (Im not paying the ridiculous Suzuki prices )

Thanks

When the screw tightens the threads on the side of the screw facing the head are in firm contact with the threads in the head because of the tension. Hitting the head of the screw hard a few times can help break the screw loose. The other suggestions were good too, just pound on it a few times before you try.

Has anyone experience of using Chinese inlet manifolds? They look right other than sh1tty hose clips but is quality ok?

Check at the LINK HERE, I bought some new recently made Japanese intakes for an 83 GS1100E, they came in an envelope from Tokyo. They were perfect, and the price was right. I don't know if he has them for your model.

[ajh]

thanks both, Cruz image look good, I have ordered them
Does anybody do the carb to airbox rubbers? I want to change them as well at the same time but cant find pattern parts
Cheers

[gs11ezrydr]

I have had success with a small chisel,not real sharp or you will cut it, Just catch the edge of the screw and tap it in the proper direction..removed many that way...A lot of good ideas out there...

[ajh]

I have had success with a small chisel,not real sharp or you will cut it, Just catch the edge of the screw and tap it in the proper direction..removed many that way...A lot of good ideas out there...

Thanks, I tried an old screwdriver and then a centre punch but both were cutting in and not moving the scew so I stopped because I didnt have the new manifolds. When I next try it I'll get a little more 'persistent'

[ajh]

So got around to changing the inlet manifolds today so if it helps anyone else heres the details. Got Cruzinimage replacements (great service, good price and they look quality). I managed to get an impact driver to loosen 7 of them by using 1/2 inch extension bars, a 6 inch and a 4inch and moving the airbox just enough out of the way. The last screw (outer left bottom screw) was difficult to get to and rounded so I got some large pump pliers on the inlet manifold and turned it and it loosened the screw.
2 o rings were broken and one manifold the rubber had come away from the metal so all replaced with new allen screws and plenty of copperslip, made a big difference, runs great except now have a fuel starvation problem on full throttle to investigate. Expected a trapped fuel pipe but not so. Bit weird, Im sure it wasnt there before I did the manifolds today but then maybe as its running better its highlighted the problem

[bwringer]

Yep, a right angle drill or right angle adaptor, preferably with a left-hand drill bit, will make short work of these accursed screws. No need to be gentle or delicate.

And yep, if you can get one loose, just twist the boot to get the other moving.