GS650 GL - how to get the carbs on and clamped

[spchips]

Anyone who has one knows what I mean. The airbox boot clamps always want to pull off. Once I came up with this approach I never had trouble again. Rein asked me the question, so I figured I'd post it so everyone can benefit.


There is a trick to getting the clamps to stay on.

Once you have the carbs all set and inside both the engine and airbox boots, take 2 mid-large sided screwdrivers and Jam them between the back of the airbox and the frame. This will hold the boots on while you are tighening down all the clamps. The clamp on the tube between the air filter box and the airbox should be loose during this.

When tightening down the clamps on the airbox boots, be sure that you go slow and evenly, thay they aren't pinched on the bottom and are fully engaged (all four at once) , and that the clamps are as far up on the carbs as possible. Also make sure the boots are in the airbox correctly, as sometimes they get pulled out a little.

[QUOTE=Rein]
I'm having trouble slipping the airbox boots onto the carbs. If I tighten the clamps, it squeezes the boots off the carb. Should they just be tightened lightly? Or are my air box boots done?

[skidMarkNZ]

Oh good man! yep that helps me!!! thanks for posting dude.

[Rein]

Just saw this on a search, this indeed, is a very useful method!

[duaneage]

Don't scrimp on violence, curse words, beer and hammers.

[roguecreature]

anyone else out there having fun with this?

sooo..i took out the air box, the 2ndary airbox (one that attaches to carbs), and carbs...

today was able to reset the carbs inside the in-take boots. dont ask me how. not really sure. it seemed the left side of the bike went in really easly and i had to fight to get the right side in....

now im trying to get the 2ndary airbox (correct me if im not thinking of the correct name) to attach to the rear of the carbs...once again it seems like it wants to connect on the left pretty easy peezy.

the remaining three did not want to budge. finally after not scrimping on cursing, tantrums , & alcohol, i decided it was time give up for the day. i think tomorrow im buying cheap new screw type clamps. those old ones suck.

any recommendations how to get those damn rubber shoes to get around the back of the carbs?
ive already tried loosening the main airbox and pushing the 2ndary forward.... i think i see someone already mentioned using WD and/or silicone to helping things slide...at the moment...they seem to be around the carbs, but just wont stay long enough for me to clamp them down, or the clamps fell appart..

after these clamps, time ot see if she will fire

[cowboyup3371]

Put the carbs into your airbox first then slide forward into the intake boots.

[tkent02]

sooo..i took out the air box, the 2ndary airbox (one that attaches to carbs), and carbs...

today was able to reset the carbs inside the in-take boots. dont ask me how. not really sure. it seemed the left side of the bike went in really easly and i had to fight to get the right side in....

now im trying to get the 2ndary airbox (correct me if im not thinking of the correct name) to attach to the rear of the carbs...once again it seems like it wants to connect on the left pretty easy peezy.

the remaining three did not want to budge. finally after not scrimping on cursing, tantrums , & alcohol, i decided it was time give up for the day. i think tomorrow im buying cheap new screw type clamps. those old ones suck.

any recommendations how to get those damn rubber shoes to get around the back of the carbs?
ive already tried loosening the main airbox and pushing the 2ndary forward.... i think i see someone already mentioned using WD and/or silicone to helping things slide...at the moment...they seem to be around the carbs, but just wont stay long enough for me to clamp them down, or the clamps fell appart..

after these clamps, time ot see if she will fire

Apparently you have a 650, which has one of the hardest airboxes to fit. 650E, G, or L does not matter, the airbox is a bitch. There is no easy way to do it. Save yourself some pain, get new airbox boots. The old ones have shrunk and are hardened, they will probably leak anyway. Your particular bike is hard enough even with new boots.

Since you really don't want to have to do this twice, have you cleaned the carbs completely, replaced the intake O rings and fixed the leaky cam chain tensioner? How is the condition of the intake boots?