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Changing Air Box boots

Vmass

Vmass

Forum Sage
Past Site Supporter
1980 GS1000S air box boots, can they be changed/replaced without too much trouble?

Any special tools needed?
 
Vmass said:
1980 GS1000S air box boots, can they be changed/replaced without too much trouble?

Any special tools needed?
Click to expand...
If this question is related to your issue of fitting the air box you have on your CV carbs, forget about it as the "CV air box" is larger than the one you have to allow for the larger boots:(
Trust me, I had the same issue...
 
Changing the boots is easy under normal circumstances. My guess is you may have to dremmel the port holes in your front airbox section to open them up a little before the boots will fit. Shouldn't be too bad as long as you carefully mark the cut line before going at it.
 
He is talking about replacing the boots in the correct air box for the '80 1000S.
These are the ones with the metal sleeve that retains the boots in the box.
Thanks for any tips.

Daniel
 
7981GS said:
He is talking about replacing the boots in the correct air box for the '80 1000S.
These are the ones with the metal sleeve that retains the boots in the box.
Thanks for any tips.

Daniel
Click to expand...

Guess I'm skipping ahead too fast with my response. Sorry about that.

In another thread Vmass details how he purchased a GS1000 VM carb front airbox assembly which won't fit on his ST with CV carbs. I made the assumption that he was trying to adapt the airbox for use on his bike by installing the proper boots, which in that instance are of larger diameter than the VM boots. I think (haven't tried) that the airbox could be adapted by opening the holes, thus my response above.

In terms of changing the boots, the process involves first pushing the metal ring out and then removing the rubber boots. It may be easier to push the metal rings into the airbox. Once the ring is out, the boot itself is easy to remove.

If the intent is to rework the airbox to take the larger boots, both the larger boots and the rings will be required.

BTW, when ordering clamps for these boots from Suzuki for my own ST they sent me the wrong clamps. I think Suzuki has a mistake in their parts fishe. To get the proper clamps I had to order them from a 1000G model, which are the correct part.
 
I, also, would have assumed that he was going to modify the '79 air box as well. ;)
Thanks for the tips!

Daniel
 
Thanks all.... Daniel is correct. I have found the correct box that needs new boots.
Trying to determine if these can be replaced without too much trouble, assuming the boots are available.
 
So, I think I finally have the correct air box. The boots are junk. I would appreciate a little more detail from an expert air box boot replacer!

Push the metal rings through, to the inside of the box with a large flat head?

When installing the new ones do you first put the metal ring in the boot and push it in the box as one unit?

Are the metal rings reusable?
 
At best its a wrestling match. Put the boots out in the sun or warm them with a hair dryer. Contrary to what everyone else says mine were a bit$h to get in but it was winter still and cold. I pushed them in with 2 screwdrivers but use larger ones so if they slip they wont punch a hole in your new boot
 
Hi ALL . I am waiting for my new intake boots to arrive. My airbox ( satandard one) has the rings in them.

Question is with the new boots can I leave them out or must I put them in. Why would there be different versions ie some with the rings some without?

Mine is aN 81 850 with the cv carbs.

we are having some very bad weather here at the mo with some minus celuis temps air temp and the boots I recently refitted were an absolute pig.

Thanks chaps
 
You need to put those ring in. If you're lucky you'll find it an ok job like me. And don't be shy about asking for Vaseline at the chemists.:D
 
FYI: Removing the old boots was simple. The metal retaining ring is split. Simply find the split, put a flat head behind it to pry it apart, grab with a pair of plyers...Done.

I ordered new retaining rings with the boots, prior to knowing that they can be removed easily and most likely reused.

I hope to have the new parts for the weekend.
 
thanks hampshiredog, but what are they for?

anybody ever taken them out- what difference will it make?
 
The metal clips make sure that the rubber seal against the airbox is tight plus when you are installing the box / carbs the boots don't come adrift.
 
Hi Hampshirehog.

Im not sure we are both on the same page? They are sleeve like rings approx 5cm wide? They were found on the inside of the boot when looking into the airbox from the carb side.

these things are solid rings/sleeves.

thanks
 
RHODESIA SMITH said:
Hi Hampshirehog.

Im not sure we are both on the same page? They are sleeve like rings approx 5cm wide? They were found on the inside of the boot when looking into the airbox from the carb side.

these things are solid rings/sleeves.

thanks
Click to expand...

Are you sure about 5cm wide? That's 2 inches in old money. The rings I'm on about are made of a strip of metal about 1cm wide and rolled in to a ring.
 
Hi Hampshire Hog,

I got the boots today and fitted them onto the airbox. These rings that came out of the old ones dont even fit in the new ones. it is a loose fit so they will just fall out. I checked if perhaps the boots were too big for the carbs, but no... fits perfectly.
I am going to leave the rings out. cannot figure out what they were for in the first place other than to maybe keep the old boots tight in the airbox? These rings do not look "home made" and are exactly the same in material and diameter as the carb inlets in the inside and outside.

When I did my bike licence in the UK , I did not do the direct access route, could maybe this bike have been fitted with some kind of gadget that does that 33bhp limit MALAKI , and the rings have been left behind when the system was taken out- or some kind of mod. I know they did not have TEH 33bhp rule in the 1980's and I have it on pretty good authority that my bike has been local for at least 20 years? dunno ..........dont really care as long as it goes like stink when done! cheers for the info anyway.
 
We're definitely talking different things and those rings you have got in there aren't standard.

The 33 bhp restrictor kits all sat head side of the carbs and were basically a big washer (restricted inlet diameter was the method of killing the horses). Last time I knew the washers were costing around ?150 - what a rip off.
 
oh ok. I was a bit of a renegade and just rode big bikes from the start. My plan was that if i was pulled by the rozzers, i would use johnny forienger defense- even though I was not one. ( see i have a heavy accent- so I have been told), ( I know me bad ..... but some laws are just dumb).

thanks for all your help
 
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