$1.50 airbox hoses.

[spyug]

Well as I mentioned in another thread, airbox hoses are on back order with an unknown ETA. As I'm impatient and wanting to get the carbs synched I started to think about alternatives.

Pods were my first thought but very cost prohibitive for K&Ns. I have in the past used cheaper ones but could never get them to work right as they are usually not restrictive enough. I did have more success on my XS with Unipods but at $100 for a set well I'll give those a pass for now.

When I pulled out one of the original hard ones and measured it up I got to thinking that a rubber hose of the right dimensions might work so I started looking around. After a few trips to diffferent stores I found a suitable rad hose in Carquest ( part number 21379).

I cut the hose to the length of the stockers and as the OD is slightly larger than the airbox holes had to wiggle it in abit. They fit very securely.
The ID is also a tad smaller than the mouth of the carb so that end too fits tight on the carb.

Originally I had placed the spring retainers from the stockers inside the tubes to hold them tighter to the box but this wasn't necessary and I actually had to remove them in order to mount the setup to the carbs. The only way to get it on was to put hoses on the carbs first then push the airbox onto the hoses.

When the carbs are mounted on the engine and airbox bolted to the frame it will be a very secure fit. Have a look:

 

[spyug]

The finished setup:

 

[spyug]

My apologies for the size of the pics. I always forget to resize them before posting.

In a further "episode " on this subject I'll show what I came up with for the missing filter box.

These may not be "kosher" and I know this will upset the purists in the group but necessity is the mother of invention and as you all know by now....I love to save money.

cheers all,
Spyug

 

[Guest]

Looks good!
It's weird seeing non-EPA idle mixture screws.

 

[old_chopper]

Awesome. Looks like you did a great job cutting the hose straight. That can be a bear to do on a large hose like that. Now take the money you saved and have a cold adult beverage!

 

[Theo]

I'm glad you posted this. I saw some flexible drain hose at the hardware store and thought the same thing you did. Now I think I will definitely give it a go. Thanks.
-Theo

 

[gearhead13]

Good luck getting them on the bike
I got so mad yesterday I was thinking of removing the box with a chainsaw

 

[spyug]

Many thanks guys.

Cutting the hose is easiest I found if you use a fine tooth saw and squish the tube as you're cutting it. A couple of C clamps on either side of the cut line can help. You can also smooth up the ends on a belt sander.

I'm quite happy with the fit as it is tight on both ends. I don't think I'll even need a clamp on the carb side. When I had the tubes in the airbox I poured some water around them and I didn't see any dripping into the box so I'm thinking I have an airtight seal. I might put a bead of silicon around just in case.

If I can , after supper, I'll pop them on and see how it goes together. I'm anxious to get this finished so i can try out my Carbtune.

Cheers,
Spyug

 

[DanTheMan]

The only downside to the fix is the fact that coolant hoses of any sort (except the plastic ones for overflow to a tank) don't handle fuel vapors well. Eventually the rubber will get slimey and deteriorate from the fumes that waft back through the carbs when you shut down.
I'm planning on buying silicone hoses like I used on my turbo (much smaller though) for my motorhome. It won't take much and will probably cost less than $20.00. Plus, I can get them in pretty colors or black if I want. They don't deteriorate or harden due to heat and fuel.

 

[spyug]

Well that didn't work so back to the drawing board.

Well that didn't work so back to the drawing board.

Well Mr. Gearhead was absolutely correctomundo. There is no way in hell that setup is going back in the frame. There is just not enough wiggle room, even with the airbox put in first.

So back to the drawing board and I guess it might be pods afterall if I can't get stock hoses.

Bummer, more time wasted.

Sorry if I got anyones hopes up.

Spyug

 

[DanTheMan]

The easiest way to install the airbox with the hoses is to assemble the whole works (aiirbox,carbs and intake boots) together off the bike. Put the entire assembly in the frame, put in the screws for the intake boots first, then the airbox screws. The biggest pain of this is the cables and small hoses, but it's much easier than fighting airbox boots.

 

[Guest]

I sold my airbox on Ebay before I threw it as far as I could.

 

[Nessism]

I sold my airbox on Ebay before I threw it as far as I could.

I love airboxes.

 

[SqDancerLynn1]

I would bet if you shortened them 1/4" they would go on !! Good job. Maybe cross the pn to a silicon hose?

 

[spyug]

I might try and shorten things up but I don't think it will change much as there really is no room to manouever and it was difficult enough getting the hoses in with the carbs and box off and on the bench. Takes a bit of persuasion.

I do have an idea for a "Mark2" version along the lines of a big pod filter covering the four carbs. Kind of like the airfilters that used to be available for cars with triple carbs..a stretched oval as it were. I can make the connector plates out of heat formed ABS and I'll be off to the hardware store for some filter foam tomorrow.

Stay tuned.

Cheers,
Spyug

 

[1982gs650E]

will the bike need to be re-tuned if i am able to fit these on properly.

I am still struggling with my airbox and the 2 inner boots just wont reach because the airbox is concaved in the middle from the heat over time.

I havent the money to put on pods and deal with all of that mess im trying to get this fixed. it is the last thing necessary to get my bike on the road and its been several months on and off with more frustration than i know what to do with...

i love this bike especially when it was running but should have not bought it on so much impulse because i need a daily driver to work and school both full time

 

[BassCliff]

Hi Mr. spyug,

This is good stuff. We're all learning along with you. I'm enjoying your journey. Keep us informed.


Thank you for your indulgence,

BassCliff

 

[Rick65Cat]

Dang!! I was hoping this was gonna have a happy ending. I replaced the carb to block boots but not the airbox ones. And mine are little hard. I should have but didn't.
I'm going to watch this thread....
If you get this to work, it should be stickied.

 

[Smokinapankake]

Ya know, Spyug, I had so much dang trouble getting my airbox to carb rubbers together that I almost sold the bike. Those 2nd Gen 750s are worse than working on an 86 Honda Civic alternator (next to the firewall, behind the drivers side wheel)!

I don't see how to get the steel rings inside to hold them in place, so they sit on the shelf in their new Suzuki packaging lookin' all pretty and smug and whatnot....

 

[GS750GUY]

I've been reading about your battle with replacing old hard air box boots.
I had exactly the same challenge when replacing the ones on my 78 GS750. Being tighter with a buck than the bark on a tree and restoring on a budget, I could not come to part with the bucks to buy new ones. So with some thought and a little enginuity I was able to make some using two sizes of radiator hose. They look and work perfectly and at a fraction of the cost of new boots.
I read in this thread that rubber radiator hose will eventually deteriorate due to fuel and engine vapors, but what the heck.......for the little money it cost me to make these, I don't mind if I have to replace them every few years. These are going on 4 years old now and still look to be in fine shape.

GS750GUY