GS450 carbs, how the @#&* do I get them back in?

[Trevor76]

Removed the carbs to remove the cam tensioner to remove the starter motor...which turned out to be working just fine, it was the battery at fault.

Anyhow I've got the tensioner and motor back in, and serviced the carbs but now I cannot get them back in.

I have the airbox mounting hardware out, so it will move freely but there's still not enough room to work with.

Any tricks to do it?

Thanks for any insight...

[86FieroSE]

Removed the carbs to remove the cam tensioner to remove the starter motor...which turned out to be working just fine, it was the battery at fault.

Anyhow I've got the tensioner and motor back in, and serviced the carbs but now I cannot get them back in.

I have the airbox mounting hardware out, so it will move freely but there's still not enough room to work with.

Any tricks to do it?

Thanks for any insight...

Pull the wires that are between the air box and the fender up and out of the way, be gentle with them. Pull the battery. Have a helper pull back on the air box and hold it. Pull the carbs back into the air box tubes. Tilt the carbs forward and down. Work them out the right side. Be easy on the rubbers. Curse. Yell. Scream. Be very very thankful...

...Theres only TWO!!!

Edit; same thing just other way around

[Guest]

If you need to use the crusty hard shrunken old ones that are there, pop some rubber grease around the inside of them and the carbs should go in a lot easier.

To get them in easier still, but new intake boots, $25.01 each from Boulevard Suzuki

[Trevor76]

I think I'll try removing the boots tonight and boiling them in wintergreen oil.
It temporarily softens the rubber.

[Guest]

I think I'll try removing the boots tonight and boiling them in wintergreen oil.
It temporarily softens the rubber.

Good luck! If you can get them to soften just a bit it will definitely help.

[Guest]

On the 81 450 I had I used a crowbar to pry the airbox back and then held it back with my shoulder while I slipped the carbs in. Never had to take the boots off.

[Mattias44]

On my 850, it was almost impossible to line up all 4 carbs perfectly with the (used) boots I bought. Some grease and a ratchet strap around the engine and the carbs did the trick. If you go that route, just make sure the ratchet isn't digging into any soft metal and the strap isn't wrapped around anything fragile.

[mpencegs]

On the 81 450 I had I used a crowbar to pry the airbox back and then held it back with my shoulder while I slipped the carbs in. Never had to take the boots off.

This is what works for me as well.. I have removed and reinstalled several times using a cats paw/crowbar to move the airbox back and up to give required room. Still a tight fit but it works.

[Trevor76]

Thanks for the replies everyone. Last night I got them back in, just a matter of getting everything lined up. I never did end up pulling the boots off, after looking at them again I realized that they were still pretty supple. Much more so than my Honda, where the original boots were hard as hockey pucks.

I found it easiest to push the carbs up into the boots, sort of in a "rolling" motion. Then I pushed the airbox onto the carbs and secured the airbox hardware. I waited to tighten the hose clamps around the carb boots and airbox openings until the end.