1982 gs650G - sealing airbox cover

[d_sal]

Hi Folks,

Just as a recap, I have a 1982 GS650G. It is my first bike, and it is also the bike that I'm learning to ride on. I have about 3 to 4 miles of riding experience. I got it for "free", I just had to pay for the backed registration, which was around $500, as well as all of the related expenses that have come along with getting it up to speed. Some might call this a newbie mistake, but I would not trade this bike for any other bike out there. If I'm not buried with it, this bike will some day be handed down to one of my kids should I have any, presumably my favorite (you all know you don't love 'em all the same).

What I've done to the bike so far:

• Completely disassembled the carbs, dipped them, replaced all of the o-rings with cycleorings o-rings
• replaced the intake boot o-rings.
• Adjusted the valves last week and replaced the breather and valve cover gaskets.

The old valve cover and breather gaskets were really dry and brittle, and after replacing them, the bike idles much better. I'm guessing there was an air leak there.

During my short ride home from school today (about 1 mi.), I noticed the idle surging at the stoplights to about 2.5k rpm and staying there. It did not do this on my way to school though, it idled at about 1100 rpm all the way there. I thought it might be the butterfly valves being held open by the clutch cable since I know for a fact this has happened, but after getting home, I verified that this was not the case. As I'm still going through the newbie to do list, I decided to take a look at the airbox cover to see if there was a leak originating from there. This is what I found.






Clearly the stripping that seals the cover is missing in some areas and needs to be replaced. Has any fellow gs650 owner gone through this already, if so what did you use to seal the box? I suppose I could try and buy weather stripping tape and cut it down to about the 3mm or so of the gap.

Also, I noticed that the air filter was pretty dry. I will lightly oil it and reinstall. How does a dry filter affect performance?

I'm currently waiting for my morgan carbtune to come in the mail, and then I will sync the carbs and set the mixture screws according to the highest idle method. I've taken a look at the intake boots, and while they're not very supple, they're also not stiff. given that they're about $30 a piece, I'm trying to hold off on buying new ones, but I think it might be best to just break down and get them before trying to sync the carbs, in case there is an air leak there as well. Until then, I'm looking to try and fix the air box cover seal.

As usual, thanks for the input.

-Daniel

[BigD_83]

I did the same thing as you are thinking with the weather stripping. I got some 1/4" self sticking, high density foam and cut it to size, then crammed it in so it would (hopefully) stick. So far it has worked out.

A dry filter is going to contribute to a lean condition, and wouldn't be helping with your hanging idle situation.

EDIT- when I was having idle issues, I noticed it was worse when the bike was hot

I'd try the carb synch and sealing everything up before purchasing new boots, even if it is a PITA to remove and reinstall the carbs.

I have a set of carb boots (manifold side) sitting on a spare head. They are in decent shape, but I can't guarantee they'd be any better than what you have on there now. I would let them go at a fair price if you don't want to go new at this time.

Are the clamps proper? Are they cinched down all the way?

[tom203]

In my opinion, sealing the air filter box cover is a waste of time- the leakage just adds to what's being pulled thru slots and drain. My bike has no gasket and runs fine. Your air fliter element needs replacing - oil ain't going to revive California sundried foam. The hanging idle is more likely to be carbs to boots leaking when warm- disturbing their fit .

[d_sal]

Thanks for your replies. I had some time, weather stripping, and booze yesterday, so I figured I'd sit down and add it. I also oiled the filter a bit as it was pretty dry, though fairly new, and reinstalled. It idles a bit better right now, but I suspect that has more to do with the oil then with the sealing.

I'm going to break down and buy the new intake boots either way, but man they're expensive. I know I can get the intake boots from Z1, but does anyone know if they carry the airbox boots? I've searched for them and have yet to find them.

Thanks,
Daniel

[BigD_83]

Thanks for your replies. I had some time, weather stripping, and booze yesterday, so I figured I'd sit down and add it. I also oiled the filter a bit as it was pretty dry, though fairly new, and reinstalled. It idles a bit better right now, but I suspect that has more to do with the oil then with the sealing.

I'm going to break down and buy the new intake boots either way, but man they're expensive. I know I can get the intake boots from Z1, but does anyone know if they carry the airbox boots? I've searched for them and have yet to find them.

Thanks,
Daniel

Boulevard Suzuki can get you the airbox boots. I just ordered a set myself for ~ 9.50 each. Z1 can get you things that are not listed on the website and are very open to discussing your needs either by email or phone (better response time)