New 1994 GS500E Owner! Intro and question

[mankyle]

Hi All,

My name is Kyle and I just purchased a 1994 GS500E from a buddy of mine.  Got a great deal because the bike  has been parked for over 2 years.  He finally tok it to a shop and they quoted him $1300 to get it running.  He decided to sell it to me instead.  From the report, compression and spark are good.  They wanted to replace the tank and $300 for cleaning the carbs among other things!!

I am very handy and comfortable working on bikes so will do all the work myself.  I rebuilt a 1976 Honda CB550 from ground up so I have experience with this (and have dealt with 4 carbs, so two should be easy ). 

The bike will technically be for my wife but I expect to ride it some too.  My bike is a 2004 Suzuki DL650 VStrom which I love!

So, back to the GS.  Before it was parked he was having running issues that started with a leaking gas cap and water in the tank, which led to rust.  He replaced the cap, Kreemed the tank and cleaned the carbs and the bike never ran right after that.  In messing witht he carbs, he bent a needle so bought new needles and carb rebuld kit but could never get the bike running right so he gave up and parked it.

So, now that I have the bike, the first order was to sort the carbs.  I have again torn the carbs apart and cleaned them very well.  I found 3 issues.  1.  Idle screws opened almost 5 turns (returned them to 2 3/4).  2. O-ring to synchro port was missing (replaced).  3.  Needle jet was very dirty and maybe clogged (cleaned along with rest of carbs).  All that has been taken care of and just waiting for a nice day to put the carbs back on the bike and see if it will fire up.

The next issue is the tank and this is where my question is (finally).  When he Kreeemed the tank, he didn't remove the petcock and so Kreemed the bottom half of the filter inside the tank (see Pics below).  This shouldn't affect regular running but will likely cause me issues if running on reserve.   From what I can tell, I can't buy just the filter, only the entire petcock.  Does anyone know of a place I can buy the filter piece, or have a filter (or whole petcock) from a scrapped tank (AdidasGuy?) or another idea?  I thought about cutting out the Kreemed part of the filter and simply using an inline filter (I know these can cause issues).  Or maybe adding a sock-type filter wired over the existing filter (again after cutting out Kreemed filter).

I will be redoing the tank (rusting through Kreem) with POR-15 (which I told him to use in the 1st place) but need to fix this filter problem.

So, anyone know of where I can get a new filter?  Or maybe a source for the sock type filter?  I've seen them on other bikes but not sure where to buy one.  Or a solvent that would dissolve the Kreem without harming the plastic?

OK, now that I have written a book as my first post I should quit

Here are the pics:
This is Kreemed side (the other side is not clogged):

[tt_four]

Welcome! we bought the gs for my wife as well, but I spent more time on it than she did.

My first guess for that filter would be ebay, or else a wanted ad in the classifieds. I know I've seen them around. you might want to pull the whole petcock apart too, he might've gotten kreem all through it as well, and you might do better to just replace the whole thing.

Cheap used:

http://www.ebay.com/itm/SUZUKI-1989-GS500-GS-500-PETCOCK-FUEL-TAP-/110812564715?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item19ccf18ceb#ht_1489wt_1163

Slightly more expensive new, but still cheap considering it's a $96 part:

http://www.ebay.com/itm/97-02-GS500-EV-K2-PETCOCK-/200691893080?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item2eba2b4358#ht_500wt_1413

[adidasguy]

There are many used ones on ebay.
I suggest one with the 2 different lengths of tubing. Makes it easy to remember which one is main & reserve. also the staggered ends makes it easier to get hose clamps on the fuel lines.
Take the worry out of it and get the new one that TT posted.

You should get a new O ring gasket if it doesn't come with it ($3) and there are 2 rubber covered washers that go on the bolts holding it to the tank (about $3 each). I know - pricey - but they keep fuel from leaking out from the bolts.

Be sure to mount it correctly: the thingy for the screwdriver to turn it on and off points to the right under the tank. It is not pointing to the left side (which seems it would be the right way but is not).

[mankyle]

Thanks for the fast replies!!

I feel a little embarrassed I didn't look at EBay first, but figured I would try my luck with members first. That link to the new one was awesome, so thank you.  In fact, I just bought it.  And yes, I like the fact that the 2 tube lengths help differentiate the Reserve tube.  The petcock was OK (no Kreem) but as you said, better safe than sorry.

Was already planning on getting the O-ring if it in't included (old one is a little worn and also has some stuck on Kreem) and wasn't aware the washers were rubber coated so guess I need to buy those as well.  Are they a GS-specific part or can I find a suitable replacement at Lowes/AutoZone? 

Also, what is the reason for putting the petcock on facing the right?  I will do so, just wondering why it is set up that way.

I am also planning a big Bike Bandit order in the near future (I know the troubles people have had with shipping but I am not in a hurry and have gift cards and an AMA discount).  I need brake pads, chain and sprockets, battery, tach cable, and a few other odds and ends.

Anyways, thanks again for the help.  I am sure you will be hearing more from me!!

[BaltimoreGS]

Petcock will fit either way but if the pivot valve is facing the right hand side you can turn it on and off with a long screwdrive, facing left you have to raise the tank to access it.

-Jessie

[Tombstones81]

how about some pics of the ride? 

[mankyle]

Will try and get pics soon.  Right now it is sitting under the house in the crawl space with tank, seat, plastic, carbs, and airbox removed so not all that exciting to look at.  When I pull it out to put the carbs on and test them I'll throw the tank, seat and plastic on and snap a few. 

f you want to use your imagination:  It is a completely stock, 1994 GS500ER in Purple with the white rims.  A little dusty/dirty from sitting but overall in great shape for the $250 I paid for it.

Kyle

[Tombstones81]

ahh the infamous 94 purple! haha
which is what mine looked like before the PO messed with it.

[tt_four]

wasn't aware the washers were rubber coated so guess I need to buy those as well.  Are they a GS-specific part or can I find a suitable replacement at Lowes/AutoZone? 


I am also planning a big Bike Bandit order in the near future (I know the troubles people have had with shipping....

Mine had the big oval washer between the petcock and tank, but it didn't have o-rings on the washers, no issues with leaking. If you wanted the orings/rubber washers just to be sure you can get when you need at lowes. They sell plain rubber washers you could put under a metal washer, they have metal washers coated in rubber on one side. You could also stop at harbor freight and grab one of these..... http://www.harborfreight.com/225-piece-metric-nitrile-o-ring-assortment-67609.html  and just put small o-rings under the metal washers. I bought one of those kits forever ago and it's super convenient to have.

[john]

Welcome.  Congrats on your custom title.  This may be a record.

[mankyle]

OK.  It was nice outside this weekend so I got the carbs and airbox back in the bike.  Got dark before I could test if it runs because  I spent the majority of the afternoon putting a new chain and sprockets on my VStrom.  Have a bunch of parts coming so soon it should be good to go (if I got the carbs sorted).

Anyways, was able to snap a decent pic of the bike so here it is.  Still needs some cleaning but doesn't look to bad IMHO.

[J_Walker]

OK.  It was nice outside this weekend so I got the carbs and airbox back in the bike.  Got dark before I could test if it runs because  I spent the majority of the afternoon putting a new chain and sprockets on my VStrom.  Have a bunch of parts coming so soon it should be good to go (if I got the carbs sorted).

Anyways, was able to snap a decent pic of the bike so here it is.  Still needs some cleaning but doesn't look to bad IMHO.

Lucky.. your's is a lot older than mine, and still looks better ^_^