Reserve and On Hoses Reversed!

[Vova]

So I did some troubleshooting following some suggestions on some other bike forums. But when it got to somewhat GS500 specific the thread died off, and thats when I knew I had to register up over here. Long story short I ran out of gas one day, knowing I couldn't be that stupid it came down to some sort of clog, which I am not mechanical but that seems really unlikely, or reversed hoses. Using a diagram I fumbled around taking apart the GS and sure enough, assuming my diagram was accurate, they are definitely reversed. One was even like only "half on," definitely looks like they were disconnected and put back on at some point, and it would obviously be easy to reverse them. Been riding around on reserve waiting to check my work so-to-speak, but so far been doing long rides where I cannot risk running empty so been keeping a full tank.

I should be mechanical, I build computers and crap, but put me around something with gears and it all goes wrong. Heck, it took me forever to figure out how to get the fairings off, and finally in a weird blast of bravery I just started unbolting things hoping I would be able to lift the tank enough to see the hoses (I guess the right bolts on the first try!).

Only damage was the plastic clip in the front holding bottom fairing to top, seems useless since there is a screw like right next to it... should I replace that or just something not to worry about? Bottom plastic clips gave me a fright but had no problems with them in the end!

So, obviously finding reversed hoses was not all that difficult, switching them seems innately more complicated. Part of me wants to get to one of my dad's buddies who is motorcycle-mechanically inclined, but no one has volunteered yet and despite my lack of mechanical luck, I do have a good stroke of bravery so figure maybe its time to just tear into it. It seems the only complication compared to what I already did is I am going to have to drain the tank of plug the hoses or something...

So tips, suggestions, step-by-step directions? lol!

[Big Rich]

As long as the petcock isn't set to prime, you can pull the hoses right off and switch them. They may drip a little when you first pull, but it wont gush gasoline everywhere.

[Big Rich]

Oops- that's assuming you have the stock vacuum petcock.

[bombjack]

Can't help you with how to test your setup, but check the hoses according to the picture below and you should be allright.

[Vova]

I did not realize there was actually a petcock deal up in the tank as well. I thought it was just a couple straws running up in there. Sounds like it will be doable without a mechanics assistance. Probably should do some other basic maintenance just by nature of the fact that its used and who knows what condition the insides are in. Got the chain tightened up though, that was the only obvious problem from the get go.

Thanks!

P.S. It would seem the best way to test it is to run out of gas. The first time I ran out of gas I had it on "on," switching to "reserve" got me nowhere. Logic would stand (would it not?) that if the hoses are reversed, I should run it on "reserve," and then when I sputter switch it to "on," and theoretically it should be working?  

EDIT: What happened was I stopped at the bottom of a hill off to the side, was not ready to try and switch it without stopping. I got it switched to reserve, and it reluctantly started up and got me almost all the way up the hill, sputtering like crazy, and it died. I figured, "hey, maybe the hoses are at the front of the tank and so going up hill won't work," so I got rolled around, fired it back up and it did the same thing, getting me only slightly further. The only thing I could think of was I did not try the prime setting, which it sounds like I should have since I did basically run all the way out of gas... but logically it would seem that would not have made the difference as the GS started up, it just would sputter and die quickly, just like it were, low and behold, actually out of gas.

[BaltimoreGS]

Bear in mind that the tank petcock can be mounted backwards.  As long as the longer nipple on the tank petcock is feeding the rear inlet on the frame petcock you are ok   

-Jessie

[the mole]

Note that different year models have different frame petcocks and slightly different routing for the hoses, so that diagram may or may not apply to you.
I suggest you carry a drink bottle with a couple of liters of fuel in it (=40km range). Run the bike till it stops from fuel starvation, then turn tap to 'prime', wait a minute then try and start it, if it runs let it idle a minute, switch to 'res' and find a service station within the next 50km. Your hoses are OK. If it doesn't run, your hoses are reversed and the tank is dry. Pour in your spare fuel, switch to 'prime' and get to a servo within 30km, your hoses are reversed. Fill up and ride as if 'res'='on' and 'on'='res'.
To lift the tank enough to change the hoses, undo the two bolts at the rear of the tank at the sides, prop it up a few inches with a block of wood or the head of a small child etc. Turn frame petcock off. You'll need a long screwdriver and come in from the right side of the tank (slot horizontal=off). Then swap hoses, turn frame petcock on, all good.

[tt_four]

As long as the petcock isn't set to prime, you can pull the hoses right off and switch them. They may drip a little when you first pull, but it wont gush gasoline everywhere.

I know you said you saw it, but make sure you actually turn off that screw right at the tank too. If you just make sure the normal petcock is on prime and rip hoses off, gasoline will definitely gush everywhere.

If your plan was just to ride around until you run out, I'd recommend riding around wiht the bike on reserve. That way if you run out you still have the option to turn it to ON  and may be able to get home. I ran out of gas on mine once, it was a big pain. Sometimes if you get it to flat ground and rock the bike back and forth it'll let just enough gas to get you home, assuming you aren't too far.

[gsJack]

That avatar looks familiar, welcome aboard JVRR.   

http://img.photobucket.com/albums/v443/jcp8832/GS500fuelcocks.jpg

[sveach]

Several people keep saying it wrong, so I wanted to jump in and clarify.

Several people said to turn the frame petcock off. They meant to say TANK petcock.

It doesn't matter what position the frame petcock is in, gas will still pour out of those two nipples unless you turn the tank petcock off. It's fairly easy to do.

Unbolt the two bolts at the end of the tank by your crotch. Lift the tank up about 6-8 inches, and if you have something to prop it up with (block of wood, or a small childs head like mentioned earlier  ), prop it up. The petcock is on the clutch side of the tank, but you have to look at it from the throttle side. You will see a knob that you have to turn with a flathead screwdriver. Try and find a nice long one. Turn it so the line is perpendicular to the nipple. This will stop the flow of gas through both nipples. Then you can unclamp the hose clamps with pliers, move them down, and switch the lines.

You don't need any mechanical experience to do this, promise. It's two bolts, lift the tank, turn the petcock, switch the lines, turn the petcock back, lower tank, put two bolts back on.

You don't have to remove fairings or anything, to do this.

What makes this process fun...is doing it with a full tank, and not having anything handy to prop it up! I've done it many times. Just have to get good at holding it at a weird angle while you peer under the tank, and try to get the screwdriver into the slot to turn it. 

[Vova]

Thank you for the responses everyone. The diagram I used was provided by GSJack, and showed different model years so I am pretty confident I was looking at the right thing. That is interesting though that the petcock itself could be backwards, though it seems the simplest and most likely explanation is the reversed hoses.

To be fair the bike is used, but it is in pretty impeccable shape from what I could tell, and more importantly my dad and his buddy who combined probably have 60 years or more of riding experience, and his buddy 10+ years mechanic experience. I would be surprised to find something more complicated/severe like a clog of some sort.

The impression I got from the seller, considering the slack chain, is he is similar to me maybe- serious about taking care of it, but not exactly an expert (he knew the chain was loose, watching my dad's buddy do it, it sure was simple), so it would surprise me if something serious was wrong, but would not surprise me in the slightest if a couple hoses were reversed .