'81 gs650g air box/carb issues

[Clint]

Hello,
I have just purchased an '81 GS650G. The previous owner messed with the carburators, and added pod filters. It runs flat at about 4000 rpm, and unless you ease into it after shifting it runs flat. I assume this is due an over lean mixture resulting from the pods (hopefully.) I went about gathering the original airbox and new Uni filter, before realising I don't have the frame piece the filter mounts to. Now I can't find that piece, after searching a salvage yard and ebay. Is there a way to tune the carbs for the pods, or should I try ordering an OEM box with all the pieces. I think it's about a 100.00 bucks, if it's even available.

The carb specs are:
Mikuni BS32SS
I.D.- 34200
BORE- 32MM
MAIN JET- #110
PILOT JET- #42.5
STARTER JET- #45

I would greatly appriciate any advice you might have.

Thanks,
Clint

[twr1776]

It depends on if you have the stock exhaust or an aftermarket pipe. Have you worked on carbs before? If you have the stock pipe I would suggest going back to the OEM set up with a stock airbox and filter. If you do have an aftermarket pipe then you are probably better off going with the pods and re-jetting. The Dynajet kits are the ones most here prefer for a pods and pipe mod. I am no carb expert but see many posts of lots of trial and error when trying a pods and stock pipe mod or a stock airbox and pipe mod.

[Clint]

The stock exhaust system is still on, and no, I haven't really messed with carbs that much. I "cleaned" the carbs on my GT550, but it was a hack job at best. I want to get this GS in top shape for a summer tour with my girlfriend. Naturaly I want to do everything right on this one. She might get mean if we are stranded on the side of the road for lack of preperation on my part.
Do you agree the poor engine performance might be the pod installation?

[duaneage]

You might be able to make a temporary frame for the air filter from a clothes hanger. I had a paper filter in an air box, someone does make one besides K&N.

Tell you what. I'll pull mine out and see if I can make a frame from a clothes hanger using the plastic one as a guide. It's supposed to rain this week so I won't be going outside to play anyway.

[Clint]

Wow, that would be great! I thought about trying something like that, but with no guide, I wasn't sure how to go about it.

[twr1776]

Today 01:14 PM
Clint The stock exhaust system is still on, and no, I haven't really messed with carbs that much. I "cleaned" the carbs on my GT550, but it was a hack job at best. I want to get this GS in top shape for a summer tour with my girlfriend. Naturaly I want to do everything right on this one. She might get mean if we are stranded on the side of the road for lack of preperation on my part. Do you agree the poor engine performance might be the pod installation?

Yes, with the stock pipe you are restricting the flow through the engine with the increased airflow of the pods. I think you are better off finding the OEM box parts you need and going back to the stock set up and jetting. That would also be the most reliable and easiest set up IMHO.

[Clint]

I feel that's the best way to go too. I don't think modifications are a good way to go with my limited mechanical expirience and budget.

[twr1776]

Clint, I am sure BassCliff will be along shortly for your "official greeting". Check out his website, lots of good info on repairs, etc. If you are planning on doing some touring with the bike I would suggest you go through the wiring harness/headlight bucket and clean up ALL connections and grounds with contact cleaner and re-assemble with dielectric grease. After you do that run the tests on the stator papers. These motors are almost bulletproof and most issues are electrical IMO from not cleaning up the wiring harness properly and checking out your charging system.

[Bribird]

Hey Clint...welcome. What kind of pods are they? Uni or the K&N ones. I have a 4 into1 pipe on my 650 and I have been thinking about going with the pods and getting rid of the stock air box? If you are going back to stock I might like to buy the pods off of you.

[Clint]

I don't know for sure, but I'm almost certain they would be a brand called emgo, based on what the seller told me. Pretty sure it was a cheap fix for the problem getting the part that is missing, rather than a performance mod. You are welcome to them free of charge.

[Clint]

I did a check on the charging system, and it puts out around 12volts at 4000 rpm. From what I gather this is a bit low, but my anolog meter may not be that accurate. Anyway, I plan on putting the Electro Sport replacement parts on. They don't have the regulator for the 650, but they have a "universal" suzuki one that might work.

[Bribird]

hey Clint, that is damm nice of you!!thanks, but if I go that route they need to be K&N so they would also match the color scheme of my bike. The dark red of the K&N ones is like a perfect match. I might have to start thinking about the dyno jet kit and some pods.

Let me know if need any help anything on your bike, I also have some spare parts but not the filter cone you need.....unless I ending up going to pods...then I would have a complete airbox assembly with a brand new UNI filter.

[Clint]

That is a nice looking bike you have Bri. The K&Ns would deffinately be a cherry on top, if you decide to go that route. I have them on my Guzzi and am very happy with them.

[Bribird]

Thanks Clint!, I just rebuilt it last spring/summer. I like the look of the K&N pods and if I get some more power out of it...yay. I am just concerned with the tuning of the carbs. Not a big fan of trial and error.
When I built my V65 Magna it was a total pain..carbs on and off too many times, make a jet adjustment only to find I didnt go big enough, then jumped 2 sizes only to find I went too big. The slow jets at least I got lucky with them being just 1 size up.

[duaneage]

I did a check on the charging system, and it puts out around 12volts at 4000 rpm. From what I gather this is a bit low, but my anolog meter may not be that accurate. Anyway, I plan on putting the Electro Sport replacement parts on. They don't have the regulator for the 650, but they have a "universal" suzuki one that might work.

I offer Honda RR kits for 40.00 that are quite popular around here. Guaranteed to work on your 650G.
Tomorrow I will see about how to make a cage for that air filter. Sometimes people spray start fluid in there and it distorts and destroys the plastic cage.