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dkl 03-09-2014 07:16 PM

GL1100 Single Carb Manifold Option
5 Attachment(s)
I know there are a lot of 1100s out there with trashed carbs, the bike isn't worth enuff to justify a carb rebuild, or to buy an expensive Kit, and still not be sure what you will have when you get done......Well after building a single manifold a month ago out of sch 40 PVC and loving the reliability and result, I decided to put my Hardware skills to use and come up with a cheap, easy, alternative build for the Mechanically Challenged. Now if your gonna get into a discussion of air flow, torque, and BLAH-BLAH-BLAH. I don't have a clue. This is a cheap and easy way to make a GL1100 run, and mine runs GREAT.
All fittings are 1" schedule 40, and available at your Local Hardware Store (like I owned for 35 year), or Lowe's for about $12. The only modification to the fittings are the 4 45degree ells, they must be trimmed a little where they attach to the 3 way tees in order to get the correct width to match the 4 stock rubber manifolds(the sch 40 1" fitting will fit perfect inside the rubber manifolds). The Polaris rubber carb mount is available on e-bay for 10 to 20 dollars, depending on which carb you choose you probably will have to make the mounting holes a little wider.. I used a VW pict 34-3 carb, new they are around $ 100, used they run the gamut......But the carb choices are endless.......My bike runs great, no Hydro-lock, no syncin, no ethanol problems,,,,,,,, I like it a Lot.......
List: All 1" sch 40 fittings....2 ea 90 degree St Ells...2 ea 3 way Tees (or side outlet Tee)...4 ea 45 degree Ells, I ea Reg Tee...1 ft sch 40 PVC Pipe....4 new screw clamps for rubber manifold (old clamps will not close tight enough)--or you can use 4 ea 1 x 1 1/4 slip bushings in the rubber boots they fit perfect but you need to ream out pipe stop at end of bushing, then you would use your original clamps...1 ea Polaris rubber carb mount...Ur choice carb. Go to Page four for new version

PatrickW 03-09-2014 07:49 PM

Seems like a good cost-effective solution, especially if you buy a bike without carbs. I think the only thing I would really be concerned about is carb icing during the winter.

6adan 03-09-2014 09:37 PM

This would also be good if you buy a bike that is not running, just to check the engine before doing anything else.

jh1990 03-09-2014 09:45 PM

Thanks for doing this DKL. I started building one using your earlier thread as an example. This one seems much easier. Don't have to deal with Saddle Tees.

dkl 03-09-2014 10:07 PM

At page 4 Important update..

jh1990 03-09-2014 10:28 PM

How long of a trip have you been on with this set up? Notice anything different between your new and old version?

dkl 03-09-2014 10:50 PM

Rode pretty much all day, short trips no long hauls, 20 miles on the interstate longest trip,no problems...Starts immediately, no bog anywhere, but I haven't let her rip yet, tires are terrible. On initial start in morning, it takes longer to warm up and fall to idle than OEM set, after it warms up it idles great,, but it does start everytime you touch the button. If you go ahead and take off when it cranks in the morning it runs fine and warms up on the road. I have a 82 with stock carbs that runs perfect, the converted 81 feels like it has more power, but with the early to say.

Sergey 03-10-2014 12:29 AM


Originally Posted by PatrickW (Post 3018193)
I think the only thing I would really be concerned about is carb icing during the winter.

My GL is a European (Japanese) one and has no heating tubes in stock. When I ordered the manifold for single carb from California the seller was a little bit surprised when he knew about it. Anyway I already run 7K miles with single carb kit but never met icing problems.

jh1990 03-10-2014 12:36 AM

Your carb and polaris mount seem to fit quite well. I'm running a pict 30. The smallest hole to hole polaris mount I could find was 2 1/4". The pict 30 is just above 2" hole to hole on the mount. I'll also need to trim some material off as the polaris mount interferes with the carb operation just a tad.

Just a heads up if anyone is trying to decide what carb to use. I may have picked a less than ideal polaris carb mount though.

tunaboy 03-10-2014 05:47 PM

It would be great to have a cheap reliable single carb that the average guy could piece together. Have to keep an eye on this one.

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