Carbs Just Rebuilt plus upgrades, Engine bogging in low rpm, Exhaust Popping

[Chef GS500f 06]

What's Up? Ok, i've done some work to my 06 gs500f, it took me close to a month to do everything. Katana Rear Wheel, Katana Shock, 15T front sprocket, 41T rear sprocket, lots of painting little things, led's front and rear, Jardine Full Exhaust, K&N Lunchbox, Vortex Clip-on's, alot more stuff. I will post pics when I figure out what's wrong.

Here we go- Took carbs out and am running 22.5 pilot, 65 mid-main, 147.5 main, 2.5 turns.  Other than about two hoses just hanging (after research found out that's what they should do) I think I hooked everything the correct way. The bike took a minute to get started and there was quite a bit of popping and a little smoke coming from the exhaust, but it being brand new, I expected it. 5 min of letting it idle on pri I switched to on and the bike died. Back to PRI the bike started up fine. I took it on a 20 min ride, the bike dosen't want to run in the ON position, but dosen't die in PRI. So I rode it in PRI, the bike feels like its sputtering in the low rpm's, I'd say 1000 to 5500 its feels like its running out of gas and then it kicks in like a maniac. The bike feels twice as fast with all these upgrades, but I can't go in the low rpm's. Also it popps a little when the engine is reving down. I really want to get the bike running good, but its not a minor sputter, I can slam the throttle and it sputters and then kicks in around 5000 rpm's.  Where should I start??

[Chef GS500f 06]

 :dunno_white:Ok, i'm sure the hoses have nothing to do, it seems that my air mixture screw needs to be played with, its at 2.5, I read here that someone with my set up has 3.25 so maybe I'll start ther. What you guys think?

[Chef GS500f 06]

Ok, i turned the screws out a more, its running better, but only in PRI, high idle and then dies in RUN position. Why is this??? Just took it for a ride, its dying in RUN position, bogging in low rpm, what next?? Float Valves?? Could it be my Spark Plugs??

[Whatever6060]

You have the fuel lines switched on the petcock.  Did the same thing myself. 

Also, that set-up is too rich.  Probably part of the reason for the bad throttle response.  I am running 22.5, 65, 145's with lunchbox and an F1 exhaust (now, was previously runnning a wileyco) and 2.5 turns and it's too rich.  I think I'm going to try 20, 62.5, and 140.  Anyone willing to trade for jets?     

[ben2go]

You have the fuel lines switched on the petcock.  Did the same thing myself. 

Also, that set-up is too rich.  Probably part of the reason for the bad throttle response.  I am running 22.5, 65, 145's with lunchbox and an F1 exhaust (now, was previously runnning a wileyco) and 2.5 turns and it's too rich.  I think I'm going to try 20, 62.5, and 140.  Anyone willing to trade for jets?     

I agree and also make sure the vacuum hose from the carb to the petcock is connected correctly.
Try this to check your hoses. http://www.bikebandit.com/houseofmotorcycles/suzuki-motorcycle-gs500f-2006-fuel-chicken/o/m9752sch510180

[Unknown]

I have the same problems with my petcock..so I've been running it in reserve -- also, it just started popping when revving down. So I'd like to find an answer as well

[The Buddha]

OK chef - you had problems before rebuild
If yes, you thought rebuilding was an alternative to trouble shooting - OK the recent congressional decree is that, its not.

If no, what did you screw up when you "rebuilt" them.

BTW were they leaking that is all you can solve by rebuilding. all other things need to be fixed by actually working on them and trouble shooting.

Now to the others ...
Unknown - reserve works but not on I give up, OK somehting is clogged in the on section of petcock. Res and On both need vacuum to work. Pri does not need vacuum.
Maybe you should fill more fuel in it ...
Cool.
Buddha.

[Chef GS500f 06]

Budda - no problems before, bike only has 4000 miles. Did upgrades and needed to rejet. Not leaking for sure, i'm in the troubleshooting stage, just messed with floats, but now its idling really high so I need to put that back the way it was, hoses are ran right I think,messed with idle screw, helped out a little with the sputtering but not fully, I don't know what to do now.  I don't know why the ON / PRI thing is doing that, the vacuum hose goes from carbs to frame mounted petcock on the back little nozzel.

Where to now?

[The Buddha]

My guess is something in the rebuild is wrong. 
High idle goes away after rejet usually, but yours acquired it 
Well you want to send me the carbs. I wont do the jets so, I'd trouble shoot and PM you when I spot somehting off. I am doing a pictorial for people too as I work on the carbs.
That will cost $22 cos in a rejet parts are $22 labor is $22.  Add shipping.
In a lot of cases getting a second set of eyes helps, so you dont do the same mistake again and again.
Cool.
Buddha.

[Chef GS500f 06]

Ok let me try a few more things and then we will see where i'm at.

[The Buddha]

Yes and let us know too what works.
Cool.
Buddha.

[Chef GS500f 06]

Well, glad to report some improvments. I went into carbs again, one of my neddles was out of the hole and I guess was messing things up, also the high rev was due to trottle cables(those things can be tricky). Bike starts like always, idle is good, but died in ON and runs in RES, . Minor sputtering in low rpm below 3750, but i'm gonna work on air screw and hopefully that will fix it. My hoses are ran right and the petcock is good, I checked today, why won't it run good in ON position? Thanks Guys. Chef

[beRto]

Well, glad to report some improvments. I went into carbs again, one of my neddles was out of the hole and I guess was messing things up, also the high rev was due to trottle cables(those things can be tricky). Bike starts like always, idle is good, but died in ON and runs in RES, . Minor sputtering in low rpm below 3750, but i'm gonna work on air screw and hopefully that will fix it. My hoses are ran right and the petcock is good, I checked today, why won't it run good in ON position? Thanks Guys. Chef

How did you check that the petcock is good? Mine looked fine when I took it apart, but it was still giving me fuel starvation problems (fixed with a new OEM one). I think the diaphragm hardens over time and makes it difficult to allow fuel to flow.

That being said, I would first check that the vacuum line from the left carb to the petcock is present and in good condition (no cracks etc).

[ben2go]

It could be that the screen on the tank petcock is blocked by dirt and/or rust.

[Chef GS500f 06]

I just took the frame petcock apart and by eyesight it looked good, maybe it is bad, same with tank petcock, I would like to replace both. When I get home I'm gonna post some pics of the hoses just to make sure there right. The bike is just sputtering a little especially when I slam the trottle, slow roll it dosen't sputter.

[Chef GS500f 06]

Making Sure that the hoses are correct, especially the vacuum. Here is the pic over the top.





Here is the petcock.



Going to the T connector.  The throttle cables are now under these hoses.



Into carbs. The hose looks pinched, but its more open now.





Everything looks right.  Right??  Rode it to work and back today, still a sputterin' in the lows. chef

[wildbill]

Lolz. your vacuum line is disconnected, in the second pic i see the brass nozzle on the petcock where the vacuum line should be, connect that back to the carb and then u can run the bike on res and on, pri doesn't use the vacuum line and thats why it would only work in that position.

[Chef GS500f 06]

That's the gas line to tank, i had tank out with hoses connected to tank.

[Chef GS500f 06]

AHHH! Still bogging under 6500 rpm's, changed spark plugs, used a little seafoam, check hoses again for leak or crimps, float height, and the air mix screw is 2.5, I tryed from 1.5 to 3.5 turns, not much difference.  I was reaserching and read about pluging up one hole in each carb where the slide is, i'm running the stock slides with 3 #3 washers. Has this helped anyone?

[tussey]

what did your plugs look like?