81 650E Refurb

[Shwartz]

Well I'm starting to think I should be the one with the title "Project SLOOWWW", not Shwartz.

Mine just got Slower. Ho hum...First World Problems.

[MAJikMARCer]

Carb install woes

Finally got to install the carbs this morning. I was able to get the front (engine) boots to seat, but I'm having a hell of a time with the airbox boots. Even when I had them on the bench, boots properly aligned, it was a pain. Even worse now that it's on the bike. The ends seat fine, but the middle two just dont want to align.

I gave up on it today. My frustration and back ache were bad enough for me to just set it aside for now and try again later. I'm sure I'll get it, but damn. I now know why so many go to pods. What a PITA!

[nejeff]

Finally got to install the carbs this morning. I was able to get the front (engine) boots to seat, but I'm having a hell of a time with the airbox boots. Even when I had them on the bench, boots properly aligned, it was a pain. Even worse now that it's on the bike. The ends seat fine, but the middle two just dont want to align.

I gave up on it today. My frustration and back ache were bad enough for me to just set it aside for now and try again later. I'm sure I'll get it, but damn. I now know why so many go to pods. What a PITA!

Did you get those carbs in yet? Who knows someday it may actually get nice enough to ride!

[MAJikMARCer]

Did you get those carbs in yet? Who knows someday it may actually get nice enough to ride!

Well they are in, but still not connected to the airbox boots. Kinda frustrating. I replaced one of the boots. I'm thinking I should have done all four now. I am anxious to get it running again soon though. There are a couple of bike events in KC late May and into June and one in Iowa that I'd like to try to get to. I suppose if I can always take the Honda, but it wouldn't be a cool, going to a classic bike show on a new bike.

[nejeff]

Well it's usually one or the other your fighting. One of my bikes is a GS550 and its a pain in the butt to get those middle ones on, and I have had those carbs out/in 4 times. New boots will help.

Was working on a XS400 today and had to use a 2 x 4 to get the carbs into the carb boots and the airbox boots were pliable like new, its always something with these old bikes.

[nejeff]

I was reviewing your build. Almost had a heart attack when I read you spend $60 on those little pieces for powder! Who are you having do it? You should get everything you need gathered at once and try to get on the same run. Try and jump on the tail of someone else who is having gloss black done so there is no special run just for you. Like TMCO or the other place I can't think of right now (down to the north of TMCO).

I just paint myself but I haven't gotten that far with any of those pieces. Sprayed color tonight for my 550E. Racing Green Mettallic. Hope it turns out

[MAJikMARCer]

I was reviewing your build. Almost had a heart attack when I read you spend $60 on those little pieces for powder! Who are you having do it? You should get everything you need gathered at once and try to get on the same run. Try and jump on the tail of someone else who is having gloss black done so there is no special run just for you. Like TMCO or the other place I can't think of right now (down to the north of TMCO).

I just paint myself but I haven't gotten that far with any of those pieces. Sprayed color tonight for my 550E. Racing Green Mettallic. Hope it turns out

I've been using CrossLinc. Jeremy is great to work with. Small operation so he's sometimes backlogged, but the price is good and the results are very nice. I'm sure I could have done better with more parts at once. I'm probably going to tear down the front end this next off season and have a lot more pieces done.

[loud et]

All I know is I caught absolute heck trying to get the airbox boots onto my 650e.
I used a heatgun to heat the airbox, with boots removed ( focusing on center two holes area) heating the airbox and then wedged a few things inside to give the center two holes area a convex( puffed out) profile, as opposed to its previously sunken in (convex) state. I let it cool and it held its new shape.
Then, with the boots installed and everything in place I very lightly lubed the boot throats, and I heated the boots and they slid on Soooooo easily.
I left it all in place with some pressure to allow it to seat......then tightened the clamps.
Yes, it is a learning curve per each bike.
That worked for me.

[MAJikMARCer]

Yea, my airbox is a bit concave as well. I think I'm going to have to try removing it and look at replacing the remaining airbox boots.

One method I tried was to remove the air filter and use a short peice of PVC pipe to push from the inside of the airbox but I wasn't really having any luck with that.

Hopefully I can remove the airbox without removing the carbs again. At least I've learned how to get them in and out quickly now.

All I know is I caught absolute heck trying to get the airbox boots onto my 650e.
I used a heatgun to heat the airbox, with boots removed ( focusing on center two holes area) heating the airbox and then wedged a few things inside to give the center two holes area a convex( puffed out) profile, as opposed to its previously sunken in (convex) state. I let it cool and it held its new shape.
Then, with the boots installed and everything in place I very lightly lubed the boot throats, and I heated the boots and they slid on Soooooo easily.
I left it all in place with some pressure to allow it to seat......then tightened the clamps.
Yes, it is a learning curve per each bike.
That worked for me.

[loud et]

Yes, I pushed and pushed to no avail. But after adding the heat they slid right on.
It truly is the ultimate trial and error thing.
You will surely get it!......eventually. lol

[GS650E_81]

It was a nightmare trying to get my airbox back on. Try lubing up the rubber throats a little and use a ratchet-strap if you have one.

I will most likely never put the airbox back on if I got to clean the carbs again. I will go the pod route!

[MAJikMARCer]

...if I got to clean the carbs again. I will go the pod route!

After this reinstallation I can certainly understand why people go the pod route!

[MAJikMARCer]

Well I finally managed to get the airbox on, but I forgot to connect the throttle cable before I got everything hooked back up. Now it's looking like i have to undo all of that just to get the throttle cable connected. UGH!

I can appreciate the engineering to get all of this to fit into a tight space, but damn, what a pain.

[loud et]

Well I finally managed to get the airbox on, but I forgot to connect the throttle cable before I got everything hooked back up. Now it's looking like i have to undo all of that just to get the throttle cable connected. UGH!

I can appreciate the engineering to get all of this to fit into a tight space, but damn, what a pain.

I did the same thing.....and that intake boot, #3 I think , is solo close to the the throttle cable bracket.
I manually opened the butterflies all the way and wedged them open, which "rolled" the throttle plate toward the rear of the bike, putting the hole/ slot where the cable goes into a bit more near the top. Then I was able to manipulate the ferrule of the cable into the slot.
It took a few screwdrivers to guide the ball into place, and as I said , that intake boot is very close to the bracket. But I got it.
Also leave the cable free from the bracked ( the double nutted carb bracket) it will give you more slack to get the ferrule / cable manipulated into place.

[MAJikMARCer]

Got it

Took her for a spin down the road. I was going to rebuild the front end next, but I think I should do the rear, at least the shocks. It may have simply been low tire pressure, but man that rear end is squirrely. Not dangerously so but enough for my confidence to drop a bit. Though I did hit a small bump and the front forks bottomed out, so they need it too. Never ends.

The car is getting new brakes and tires first though...That'll set me back about $1500 right there. Not going to buy another sporty car, I'll stick with bikes for that from now on!