GL1100 Cheap E-Z Single Carb Conversion
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- Cast Iron Member
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GL1100 Cheap E-Z Single Carb Conversion
**Qualifications: I know nothing about Air Flow, Torque, or Carbs..But I owned a Hardware Store for 35 years**
**PVC Intake Manifolds have been used before, and I have seen no record of failure, I make no claims of Safety. This is just what I did, and it worked for me, and I have no control over the quality of your workmanship.**
GOAL: To make a single carb manifold for the 1100 that anyone, even the mechanically challenged, can build easily, with parts that are readily available and cheap.
Material: Sch 40 Pvc Fittings 1" size---4 each 45 elbows (70 cents per)--2 each side outlet tees($2 per)--2 each 90 elbows(50 cents per)--1 each reg tee(65 cents per)--1 each 1" Pvc Conduit 45 degree Sweep Elbow($4 per)--1 ft 1" Reg PVC Pipe not sch 40(40 cents)-- 4 each hose clamps--1 each Polaris rubber carb mount(e-bay, ($10-$20)--VW Carb pict 34-3(ebay new $100 used ??)
Modifications:
A. 4 each 45 elbows, you must cut less than a quarter of an inch off the ends that fits against the side outlet tee(to obtain correct width so end of 45s will fit inside existing rubber manifolds, you must use the new hose clamps to clamp rubber manifold boots onto fittings.
B. 90 elbows, cut half the glue socket off the end that mounts on top of side outlet tee. (to lower height of manifold)-(you also could cut half of glue socket off the top of side outlet tee, if you desire to lower it even more).
C. Cut the 45 conduit sweep ell for the two pieces that attach from the middle tee to the ells at each end. The section for each side will be about 2", the cut needs to begin about 1" after the bend begins and go back 2" toward straight end. (this will give you correct angle so every thing will slide into rubber boots perfectly)
D. Polaris Carb boot, depending on which carb you use, you will have to enlarge two mounting holes for carb to fit into flange, a small amount of rubber will also have to be removed, so carb linkage does not rub.
E. I used 1" regular Pvc to make the small pieces to butt join the fittings, I used it so the inside diameter would be larger, and to do away with any ridges inside manifold.
F. The only throttle cable used is the pull cable, and I used a Mending Tee plate attached to drain hole on VW Carb with an eye bolt attached to mending plate to attach throttle cable. (This added another $4)
Result: Carb was super easy to adjust, idles between 1050-1150 smooth, Bike will roll off stop real easy, or real hard, bike will cruise around town enjoying the day, with out loading up, missing, or flat spots, and goes back to idle at every stop. On highway it has plenty of power, is strong, and responsive. I have no idea on potential because it is to fast for me.**SUCCESS**IMPORTANT GO TO PAGE TWO FOR FLAT ACROSS ENGINE VERSION.....IT IS JUST AS EASY
**PVC Intake Manifolds have been used before, and I have seen no record of failure, I make no claims of Safety. This is just what I did, and it worked for me, and I have no control over the quality of your workmanship.**
GOAL: To make a single carb manifold for the 1100 that anyone, even the mechanically challenged, can build easily, with parts that are readily available and cheap.
Material: Sch 40 Pvc Fittings 1" size---4 each 45 elbows (70 cents per)--2 each side outlet tees($2 per)--2 each 90 elbows(50 cents per)--1 each reg tee(65 cents per)--1 each 1" Pvc Conduit 45 degree Sweep Elbow($4 per)--1 ft 1" Reg PVC Pipe not sch 40(40 cents)-- 4 each hose clamps--1 each Polaris rubber carb mount(e-bay, ($10-$20)--VW Carb pict 34-3(ebay new $100 used ??)
Modifications:
A. 4 each 45 elbows, you must cut less than a quarter of an inch off the ends that fits against the side outlet tee(to obtain correct width so end of 45s will fit inside existing rubber manifolds, you must use the new hose clamps to clamp rubber manifold boots onto fittings.
B. 90 elbows, cut half the glue socket off the end that mounts on top of side outlet tee. (to lower height of manifold)-(you also could cut half of glue socket off the top of side outlet tee, if you desire to lower it even more).
C. Cut the 45 conduit sweep ell for the two pieces that attach from the middle tee to the ells at each end. The section for each side will be about 2", the cut needs to begin about 1" after the bend begins and go back 2" toward straight end. (this will give you correct angle so every thing will slide into rubber boots perfectly)
D. Polaris Carb boot, depending on which carb you use, you will have to enlarge two mounting holes for carb to fit into flange, a small amount of rubber will also have to be removed, so carb linkage does not rub.
E. I used 1" regular Pvc to make the small pieces to butt join the fittings, I used it so the inside diameter would be larger, and to do away with any ridges inside manifold.
F. The only throttle cable used is the pull cable, and I used a Mending Tee plate attached to drain hole on VW Carb with an eye bolt attached to mending plate to attach throttle cable. (This added another $4)
Result: Carb was super easy to adjust, idles between 1050-1150 smooth, Bike will roll off stop real easy, or real hard, bike will cruise around town enjoying the day, with out loading up, missing, or flat spots, and goes back to idle at every stop. On highway it has plenty of power, is strong, and responsive. I have no idea on potential because it is to fast for me.**SUCCESS**IMPORTANT GO TO PAGE TWO FOR FLAT ACROSS ENGINE VERSION.....IT IS JUST AS EASY
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Last edited by dkl on Fri Apr 25, 2014 7:32 pm, edited 1 time in total.
- El_Taco
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Re: GL1100 Cheap E-Z Single Carb Conversion
If it works, it works. What's the difference in I.D. between Sch40 and 80?
Cost me $6 and a couple o-rings to go through the factory carbs on my 77, were yours completely trashed?
Cost me $6 and a couple o-rings to go through the factory carbs on my 77, were yours completely trashed?
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Re: GL1100 Cheap E-Z Single Carb Conversion
I purchased two 1100s for $600 last year, I was able to put the two together and make one really good 82 naked bike (pictured). I also had bought a 1100 fully dressed but in pieces two years ago, it came with an extra engine on a pallet. I fixed the dresser and rode it for year, but all the fairings and weight are not for me so I sold it. Long story short, I had a good engine but no carbs. The carbs in the picture were DOA, they had been taken apart, canabilized, and most every bolt stripped. I had access to a VW carb, and the rest is history.
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- Casper
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Re: GL1100 Cheap E-Z Single Carb Conversion
I'm with El_Taco, if it works then good on ya mate. A novel approach for sure. In the one picture of the system mounted they look silver, did you do a coating? Do you happen to know what the upper working temperature of PVC is?, just wondering how close you get once the bike gets warmed up. How long have been running that set up?
1976 LTD, Being Returned to Stock
Standard 1976 GL1000 Being Morphed into the Alberta Super Clipper
Standard 1976 GL1000 Being Morphed into the Alberta Super Clipper
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Re: GL1100 Cheap E-Z Single Carb Conversion
I first built this set two or three months ago out of 1 1/4 PVC, I have run it on some fairly long hauls, and I have seen no problems from heat. I went to 1" to increase the suction so it would idle better, and it worked... PVC SCH 40 is designed to carry liquids up to 140 degrees F. under pressure. The biggest problem with an intake manifold is icing, so heat coming up off the engine is a non-factor, in my opinion, but that's what it is, just an opinion. The silver you see is bumper chrome paint, nothin' special.
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- El_Taco
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Re: GL1100 Cheap E-Z Single Carb Conversion
I figured you would only go to such lengths given the necessity, knowing the price of replacing the rack. Do you have any pictures of the end result?
How many miles do you have on the current setup?
How many miles do you have on the current setup?
- hacksaw1945
- Silver Member
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Re: GL1100 Cheap E-Z Single Carb Conversion
As a Master Plumber I am impressed
1977 Honda GL 1000, 1982 Honda GL 1100I went naked, 1976 Honda LTD rough long range project, 1945 Indian Chief, 1947 Indian Chief, 1948 Indian Chief, 1958 Cushman Highlander, 1959 Cushman 3 wheel Mailister, 1966 Triumph TR6,
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Re: GL1100 Cheap E-Z Single Carb Conversion
This bike was made from leftovers in my shop. It is not legal yet, so short hops of a hour or so on country roads is all I have. So far I have experienced no problems at all, but until new tires come in, I can not say how it will perform using a very aggressive throttle. Waiting for a fender, and some tail lights....to be legal.........will post pictures when I get farther along. Thanks Hacksaw,,,,You must know the "Plumbers' Creed"---Stuff don't run uphill, and Payday's on Friday.
- El_Taco
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Re: GL1100 Cheap E-Z Single Carb Conversion
I know the feeling, I've never owned one I didn't have to tear apart and piece back together to some extent.
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Re: GL1100 Cheap E-Z Single Carb Conversion
But if it was e-zee it wouldn't be any fun, and anybody could do it.
- El_Taco
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Re: GL1100 Cheap E-Z Single Carb Conversion
We call them Rolex riders. Point, pay, instant biker. Don't worry about them, they have AAA.dkl wrote:But if it was e-zee it wouldn't be any fun, and anybody could do it.
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Re: GL1100 Cheap E-Z Single Carb Conversion
Found a 1000 front fender, and some fish tails off a Harley. Waitin' on a rear fender with signals off a 1000, and also a Kawasaki solo seat.....and will see what happens. Put a couple of 100 miles on it, slippin' around on back roads cause it ain't legal------yet.... Carb and manifold are still running better than good!!!!!!
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- Terry in Australia
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Re: GL1100 Cheap E-Z Single Carb Conversion
That looks great mate, and I love those fish-tails! Cheers, Terry.
1986 GL1200i
- sunnbobb
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Re: GL1100 Cheap E-Z Single Carb Conversion
I've always wanted to run my wing around without any feathers. That looks like fun!
I found the end of the internet
---- Bradshaw Bikes custom polishing for your wing. Visit us on facebook!
1978 Learning Experience
1980 County Road Hauler "Brain Damage"
1978 Cafe Custom Gl1000 "Vyper"
1977 Bulldog Inspired "Vaincre"
1981 Street Fighter GL1100 "No Quarter"
1983 Supercharged Street Drag "Anubis" (in worx)
1983 gl1100 mint restoration "Kristen"
1985 Aspencade..pondering.
---- Bradshaw Bikes custom polishing for your wing. Visit us on facebook!
1978 Learning Experience
1980 County Road Hauler "Brain Damage"
1978 Cafe Custom Gl1000 "Vyper"
1977 Bulldog Inspired "Vaincre"
1981 Street Fighter GL1100 "No Quarter"
1983 Supercharged Street Drag "Anubis" (in worx)
1983 gl1100 mint restoration "Kristen"
1985 Aspencade..pondering.
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Re: GL1100 Cheap E-Z Single Carb Conversion
Got rear fender off the 1000 mounted, wired, everything works perfect. Thinkin about Kawa 500 studded solo seat, any suggestions appreciated. Drivers Back rest off a shadow stays for sure, and mount off a 84 gl1200 stays also. Luggage rack off a 81 1100, that stays for sure so I can use the Samsonite case for a long haul and the platform also can carry my golf clubs.. The ugliness behind seat will be covered with throw over studded saddle bags to match seat and backrest. PS ...rode 100 miles yesterday...carb and manifold have presented no problems at all.
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