air box reassembly

[Guest]

Hi again, I am in the process of replacing the carbs and air box. I am not sure if I have the rubber pieces turned the right way. They are two shorter than the other two. I am not sure if the other one is on right it is round one side and oval on the other. You can still turn it either way.The 4 pieces that attach to the carbs and the airbox seem to not want to stay on? I am thinking I reassembled wrong. The manual I have, bought at world of power sports in Decatur doesn't even list my bike as covered? The guy behind the counter told me this was the correct one? I think he is so full of it he has brown eyes. Well anyway anybody got some pictures of one? I tried searching for it several different times but no luck. The bike is a 82 gs650L. I replaced o-rings only and dipped the carbs and sprayed carb cleaner in the carbs,I used a torch tip cleaner to clean the holes and ports. new intake boots and o-rings, new bolts. I was having gas in the airbox. I think it was the o-rings they were all pretty bad. dried out and broke.The float levels were off abit also. I lost one carb drain bolt. I think I can get one from a set of carbs I got stashed at work.I hope when I put tires on it goes this smooth.

[Larry D]

You can look up your bike at the link below. Are your airbox boots new ? For your bike, the two inner ones are shorter than the outer ones. So there are two different Suzuki part numbers. Not sure about your boots, but my new ones were stamped L or R. I put them on, spun them around until they laid flat on a straightedge. Mine were all the same length though.

If you're trying to use the old ones and they're hard and brittle, it'll be a difficult task. New ones seal better, and it's much easier to re-install the carbs because they're more pliable.

http://www.alpha-sports.com/suzuki_parts.htm

[scrapper]

I was wondering how to turn the big piece of the rubber boots between the box and the carb? On the inside of the box you can spin them around 360 degrees. There is a longer piece does it go at the top, or does it matter? You can't see it in the picture. I could tell that the other rubber piece was right. They are in fairly good shape. I was wondering how to tell how much to tighten the clamp?

[waterman]

The outside rubber tubes go with the long side out. You have probably noticed that the air plenum is roughly parallel with carbs 2 and 3, hence you can rotate these rubber tubes without any effect. The outer portion of the air plenum angles back and thus the tubes need to be rotated so that carb mounts are in line. I hope this makes some sense.

It may be easier to visualize the correct positions if you remove carbs and the plenum from bike and mate them on a bench. By the way, the plenum is held in position with a band clamp, just loosen and slide forward. Here you will see how they have to go.

I too had difficulty trying to keep those hoses tight to the carb mouths. I finally found that if I installed one side and tightened the screws then I could gently install the other side and tighten it without undoing the previous side. Hope this works for you.

[Roostabunny]

I was wondering how to turn the big piece of the rubber boots between the box and the carb? On the inside of the box you can spin them around 360 degrees. There is a longer piece does it go at the top, or does it matter? You can't see it in the picture. I could tell that the other rubber piece was right. They are in fairly good shape. I was wondering how to tell how much to tighten the clamp?

I don't know if your 650 has these, but on my 850 there was a tiny braille-type dot on the boot that lined up with a similar dot on the outside of the airbox. You can just barely see the dots on the upper rim of the boots in this photo - http://picasaweb.google.com/lh/photo...eat=directlink.

Please note that when I took that picture I hadn't figured out the "dots" yet, so the boots are in UPSIDE DOWN. So good example of "dots", bad example of installation.

[scrapper]

Thanks, I thought that something was wrong because the box didn't quite line up with the carbs. I didn't relieze the boots had to be rotated. It makes more sense. I was worried that the hood on the inside needed to be a certain way. I am going to tap out carb bowl bolt hole to take a 1/4 20 bolt. I can't find one anywhere. That should not cause any problems will it? I even went to a bolt company and they said it was something unusal. The carbs I got at work have a bigger bolt in them. I will check for the dots tomorrow. Thanks again