Tip on installing carburetor with stock airbox

[Guest]

One of most frustrating experiences in dealing with my GS1100E/ES is re-installing carburetors with stock airbox.
The main problem is, there is not an enough space to fit airbox, carburetors and boots.
In order to fit them, I need to deform rubber boots with great deal of elbow grease and muscle.

So on my latest project, I inspected space between the frame and the airbox very carefully.
As usual, the airbox hits the frame as it pushes back. But imperceptibly, the airbox also can hits battery box under certain orientation. Under further inspection, the rear brake hose near master cylinder can also hit the airbox.
By loosening the battery box and the rear master brake cylinder, I was able to open the space by at least ??!
As a result, I was able to re-install the carburetors in a breeze.

Here are additional tips.
1. install hoses (fuel, overflow) ahead
2. attach throttle (and choke) cable ahead
3. Install airbox, carburetors onto airbox, and four rubber boots (and aforementioned, loosen battery box and rear master cylinder)
4. Slide/push #4 carburetor onto #4 boot in an angle so that carburetors contact mostly #4 boot (instead of all four carburetors contacting all four boots at a same time). Spray soap water to ease sliding carburetor to boot.
5. Once #4 carburetor mates to #4 boot, tighten the clamps
6. Using #1 carburetor as a leverage and #4 carburetor/boot as a fulcrum, slide #3 carburetor onto #3 boot, and so on to #2 and #1.

Hopefully, the tips will be helpful for someone in a future.

[Rob S.]

1983 ED, I presume?

I have a tip, also. Get pods.

[tom203]

Good tips, thanks. Bunch of guys will need to absorb this. Yes, 1/4 inch is a big deal on lots of bikes.

[LAB3]

One of most frustrating experiences in dealing with my GS1100E/ES is re-installing carburetors with stock airbox.
The main problem is, there is not an enough space to fit airbox, carburetors and boots.
In order to fit them, I need to deform rubber boots with great deal of elbow grease and muscle.

So on my latest project, I inspected space between the frame and the airbox very carefully.
As usual, the airbox hits the frame as it pushes back. But imperceptibly, the airbox also can hits battery box under certain orientation. Under further inspection, the rear brake hose near master cylinder can also hit the airbox.
By loosening the battery box and the rear master brake cylinder, I was able to open the space by at least ??!
As a result, I was able to re-install the carburetors in a breeze.

Here are additional tips.
1. install hoses (fuel, overflow) ahead
2. attach throttle (and choke) cable ahead
3. Install airbox, carburetors onto airbox, and four rubber boots (and aforementioned, loosen battery box and rear master cylinder)
4. Slide/push #4 carburetor onto #4 boot in an angle so that carburetors contact mostly #4 boot (instead of all four carburetors contacting all four boots at a same time). Spray soap water to ease sliding carburetor to boot.
5. Once #4 carburetor mates to #4 boot, tighten the clamps
6. Using #1 carburetor as a leverage and #4 carburetor/boot as a fulcrum, slide #3 carburetor onto #3 boot, and so on to #2 and #1.

Hopefully, the tips will be helpful for someone in a future.

Step by step instructions are always good!

I have a tip, also. Get pods.

Why eliminate one problem by creating four more?

[Rob S.]

Why eliminate one problem by creating four more?

What, you don't have a Dyno strapped to the back of that twin?

I'm guessing you've never tried to access the battery on an '82/'83 11E. Hint: it requires a Dremel with a cutting wheel.

[closetbiker]

I snagged an 83 GS750 ES in boxes so don't know how the airbox came out. It certainly isn't obvious how to get it back in. There's nothing in the service manual. Assembled it doesn't seem to fit and in halves there isn't enough room to then reassemble it. Any tips on how this is done? Pods are the lazy man's way...I won't go there.

[cowboyup3371]

Welcome Closetbiker, I cannot speak for that bike but I would suggest starting your own thread so your question doesn't get lost in this one.

Please add your bike information to your signature block though so you won't have to repeat the information every time you turn around

[wymple]

"I'm guessing you've never tried to access the battery on an '82/'83 11E. Hint: it requires a Dremel with a cutting wheel."

I have. Nearly a blowtorch experience, IMO.

[WilliamGLX81]

What is the advise about lubricating the boots with something like silicone brake pin grease? I have a gs650, and the carbs are a huge pain to get in and out. You have to disconnect the cables and remove their guides to even fit them out the side. My boots onto the head are new, and the older ones in the airbox are very flexible.