Andrews Engine labs 1994 GS500 Rebuild *Restoration*

[Gs500+AndrewsEnginelab]

THE SHORT STORY..... The Bike DONT start..... gas in floats/refills.....gas isnt making it into cylinders.... What could be broken

Hey Guys Just bought my 94 gs500 a few days ago I have all my experience with cars and this is the first carb ive ever held in my hand so thats also a big step for me. when I got it from the P.O It was running... to say the least I got it home and started looking it over. at first it ran but the throttle was very unresponsive and was acting funny. I played with the Idle adjustment till it sounded better. attempted to ride it but the bike kept dieing if id let off the clutch. Since then I have bought new plugs. tested the ignition coils checked for spark.....I think the P.O dropped it.. on the signal generator cover/right hand foot peg and exhaust. Then I discovered if i pulled the right ignition coil the bike would keep running but if i yanked the left side the bike would die... at the time It was only running off one cylinder... since then the bikes stopped working cant get it to start. Ive checked its getting sparks on both plugs now. after I adjusted the signal generator... the magnets in the points were Brokkkkken to shaZam!... made me wonder maybe its giving me a weak spark. I'm gona replace it for sure even though i'm getting spark... also the knob attached to the crankcase looks like it wobbles when it spins which has me worried maybe the crankshaft is bent or something stupid.. regardless of all the changes the bike has gone through since ive had it... currently symptoms are ..... It seems to not be getting gas into the cylinder....the floats will fill but if i try to start it... the plugs are still dry where as before the right plug eg the cylinder that wasn't firing was getting wet... so now im shifting from ignition to fuel problem im getting spark..on both plugs... i have 140psi compression on both cylinders and the only things Ive touched since I got the bike are the Idle rpm screw and I turned the Sync screw 1/4 turn then turned it back.... Obviously I need to rebuild the carbs.... Im just wondering what i should be looking for...

[Funderb]

okay.
1. the points are not adjustable. timing advance happens in the CDI, a little black, non-programmable box.
2. these carbs don't spray gas anywhere, they pull fuel through the Venturi effect.

More than likely you have this: The signal generator rotor is not tightened properly, which could have damaged the "points" as we like to call them. You'll have to replace it as a unit if thats true.

you need to disassemble the carbs and carefully clean the passage ways and jets with little wires, carb cleaner in a can, and compressed air.

after that, re-assemble, make sure all parts are in place, make sure theres no place for air to leak in except where you want it to be,  and try to start it.

[GSnoober]

First of all, it's time to read the wiki:

http://wiki.gstwins.com/

http://wiki.gstwins.com/index.php?n=Main.Troubleshooting

http://wiki.gstwins.com/index.php?n=Main.Restoration

http://wiki.gstwins.com/index.php?n=Main.Maintenance

http://wiki.gstwins.com/index.php?n=Main.Upgrades

http://wiki.gstwins.com/index.php?n=Upgrades.Rejetting

Next, be SURE not to damage any of those finely drilled jets and passages in the carb bodies by poking wires through the holes. ALSO, you should NOT seperate the carb bodies; keep them together if at all possible.

Carb rebuilding is both an art AND a science; if all else fails, send your carbs to The Buddha (who also happens to be the admin here). The Buddha will hook you up with working carbs in no time so you can get that GS back on the road before the snow flies here in the northern hemisphere.

You can contact The Buddha through this link:

http://gstwins.com/gsboard/index.php?action=profile;u=119

Let us know what part of the world you're located in; there might be a member nearby who can stop by to provide some assistance this weekend.

Good luck with this; looks like you've got some serious wrenching to do... which some of us consider to be a good thing. I'll post a link where you can download the GS manual in PDF format as soon as I find it...

[GSnoober]

Found the link and verified that it is still working; direct link to download from is HERE:

http://www.fileden.com/files/2008/10/7/2133953/GS500-OwnerManual.pdf

More info here:

http://wiki.gstwins.com/index.php?n=Maintenance.Books

Some of us prefer to have hard copy manuals for quick reference (no computer / printer needed), so you can order one through the wiki Books link I provided if you decide you need one. More good info in this post from adidasguy, parts-whore extraordinaire:

http://gstwins.com/gsboard/index.php?topic=62167.0

[Gs500+AndrewsEnginelab]

Hey Guys Thanks so much for the quick and very helpful Info!

I live in Toronto,Ontario,Canada Born and raised 22yrs. If anyone is nearby I don't expect any help with the bike, but id never turn down some good advice! maybe we could ride together...I could definitely go to see how the breathers are routed... gas tank etc.  things were all over the place on mine.

Sorry Funderb ... I was just trying to say that no gas was getting to the cylinders. thanks for the quick replies its nice to talk to some people who have a passion for this stuff!

I've been reading a ton and will look through every link GSnoober sent me thanks again buddy!
Ill try to Be more concise with my posts.

O.k So I have some new info to share...
So I went outside and decided to try spray starting the bike...to see if the spark was good? Not sure if this counts as a test for good spark but the throttle Came back!!! so I spray start it with some carb clean and Bam She is flying with a good responsive throttle....for the short time i had it running... maybe 10seconds  this got me excited Both cylinders were sparking and would run.....off carb clean...... right away looked at my carbs and ran up stairs to research. I decided to go recheck my float level... I had checked it over the first time I cleaned the carb... put it back on Used Kerry Burtons Float height test and the fuel flowed up to the float gasket like it says in the How to... but when I rechecked them today they were coming up a fair amount below the gaskets... an obvious change from the first time i tested them.... So I looked them over.... and watched the youtube video on rebuilding the gs500 carbs           http://www.youtube.com/watch?v=nQ2Crz1wVts
I am going to go order the parts i need to rebuild it tomorrow at Snow city cycle marine my local suzuki dealer.... Hopefully they can give me a pointer at what could be causing my low float height I know there is that little metal prong that you adjust... Im going to research how to set the Gs500 floats right now and go try and do it myself before i go to the store with them. maybe fixing the float height would allow the starter jet to suck fuel which is what im assuming is not happening due to the low fuel... Sorry for the long ass posts I just get typing and it helps to put my thoughts down... Ill figure out how to post pictures and Come up with a list of things I want to do to the bike once I have it running...

[Gs500+AndrewsEnginelab]

 
Hahahaha.....
Captains log..... 3:36AM have successfully woken up my mom...

Ohyaahhhh with a little bit of tinkering and some careful looking over I put the carbs back together inspecting everything... I reaaaalllly looked over the floats... made sure they were seated and the needles were ok... not worn..... Put it back together... all the work i had to atleast check the float levels to see if i accomplished anything other then burning myself out for tomorrow morning. checked the float level Bamm good! level ! so im thinkin hmmm hmmm u know quickly turn it on .... see if it works turn it off no one will notice its only 3am.... everyones asleep right? ..... Dont wana be my neighbours hahaha theres that kid again turning his bike on at 3am ..... he musta rebuilt the carbs again!!!!   SO now its almost 4am.... I have a bike that now works!!! and I wana go fiddle with it but Cant turn it on and now im never gona be able to fall asleep... well... only like 4 more hours and I can get back out there...before school and the hvac guy shows up ...  right before I turned it off i had it idling at 3k with the choke on and then i took the choke off and brought it to 1200 with the idle screw... then i felt bad and shut down.... Great success ! Soon ill be back to normal where my only problems are the fuzzzz

[Gs500+AndrewsEnginelab]

Bike runs, sounds and feels good.  now to make it look like it isnt 18 years old... I am going to slowly go over the maintenance schedule. Oil to brakes to tightening everybolt down

any suggestions you guys have of stuff maybe you did to your gs or think would look cool!!!

Paint Job!
I want to ditch the stickers and either go red or black with the silver frame....

Fuel filter
new petcock system
K&N air filter
carbon fibre tank cover... like the Gsxr ones but without the Gsxr symbol on it.... still up in the air on this one.
New horn
New grips/foot pegs...
exhaust is a maybe.... right now the one i have is a little ugly but it works and if its not broken dont fix it... especially if it costs over 400$
I,m thinking about looking into a digital tach if anyone has experience with that id love to hear how you did it.

I noticed the dust seals on the  seals on the front shock system have big gouges out of them... so eventually ill redo the seals/oil/dust caps on my forks.... I know you need a long bar with a socket end "Special tool" sounds like a long piece of pipe with a socket attached on one end and a bolt end sticking out on the other side to put the wrench on... stick it down the tube and zap.... it all comes apart... if anyone can shed some light on that...  that will be later in the winter....

Windsheild Im totally open to suggestions link me your favorites !

[Gs500+AndrewsEnginelab]

Offcourse the 100$ Engine from a1989 that would have not only the cover but the signal generator !! wont deliver to Canada.... Damnnnn

I cant find the signal generator for less then 180$ and my rotor is bent and thats another 75$....

[The Buddha]

Andrewsenginelab now is that something like Dunlab ? (redneck dunlop).

Cool.
Buddha.

[Funderb]

glad to see that things are looking up.

is your rotor bent, or it mis-aligned? it'd be hard to bend that big ol thing. you may get away with just replacing the bolt and re-torquing the rotor. signal gens are very expensive, i was helped out by a fellow member here when mine failed. You might try posting in the Sales forum for what you need.

[Gs500+AndrewsEnginelab]

The lab puts out nothing but the highest quality of work....!
The Signal generator rotor I has yet to be pulled I will read the manual quick and take it off to see if the bolt holding it in is bent or if the rotor iteself is bent ughhh... hopefully not 75$$$$$ for the little metal rotor... this all must have happened when P.O dropped the bike on the right side ... I also found I need to weld the underneath metal bracket of the footpeg back into a box it has bent down from the peg in the drop... I assumeee

Ya I got the beast running.... road it around the block 50 times and then my neighbor who is good with anything involving engines hoped on it... he said it is safe enough but that the power is not right and that he thinks there is an exhaust leak...

I put it back in the lab and got to work ..... found that I was missing a exhaust bolt...and my flanges were loosey~goosey so I tryed to take the bolts off...*@$#$-tight grabbed the liquid wrench and the impact gun... they were friggggin tight but i got em all out no breaks. Right now these are the new parts Ive been thinking about buying and would like some info ....
I will post pictures ASAP I have been busy with school these last few days today ill get them up... this thread is boring without new pictures!  

OH BTW I now cant find my gas tank key.... cleaned the garage and the one thing i lose along with my mind... So I don't want to spend more then the 23$http://www.ebay.ca/itm/Fuel-Gas-Tank-Cap-Cover-f-GSXR1300-Hayabusa-97-07-GS500-RGV250-GS600F-00-01-/300804506987?pt=Motorcycles_Parts_Accessories&hash=item460958856b

How do I get a key for my current working gas cap...

PARTS LIST
Fuel Lines 10$
Seat spacers 2.35$
Handlebar http://www.motorcycle-superstore.com/14/71/982/36823/ITEM/Emgo-Daytona-Touring-Handlebars.aspx?WT.ac=Cart_Item 27$
K&N Air filter 44$
Pro grip 69926 10$
Emgo Ignition switch 26
Emgo fuel filter 10
LED short turn signals 28$
Signal generator cover assembly 80$$$ ouch
float bowl gaskets 20$
4new exhaust bolts
2 new exhaust gaskets 7$
spark plugs 5$
new dot4 brake fluid 10$
battery 79$ 

[crzydood17]

if you want to make it not looks ancient, upgrade the tank and the tail fairings to a 01+

[Higgins13]

Hey Guys Thanks so much for the quick and very helpful Info!

I live in Toronto,Ontario,Canada Born and raised 22yrs.

Barrie, On here. Can't help you much on build (your knowledge is ahead of mine)but I could teach ya to ride :p

Might have some extra parts your interested in...

[Gs500+AndrewsEnginelab]

Hey Higgins I will actually be living in Barrie for the next four years while I do my Bachelor science Nursing we can definitely meet up and ride sometime. Also lemme know what kind of parts you have... I am currently looking for fair amount of smaller things... just found out today my throttle tube has a big crack in it and needs replaced I would say... broken throttle anything sounds like a bad time....



I don't mind this bike so much... Its not a gsxr1000 or R6 but it also didn't cost me 7000$

I will paint the plastics in the spring along with the tank...and the exhaust is getting done in the next week or two....almost a bronze color... looks sweet... I put a bunch of cool pics of things ive worked on over the years...and a few of the bike checkkk it out!  

http://s1205.beta.photobucket.com/

[piresito]

you might want to check for "Goats Syndrome". Run a search on it, there are some guys that can help you more about it.

It's about those stator magnes coming lose, making their way to the engine and getting chewed between other metal part in the engine. A very expensive repair in that case, altough I think you had some luck and your engine might still be good, be sure you clean all the magnet pieces in it.
At the time, while I researched about this, I find out that people have previously dropped the bike to the left it most cases...

[Gs500+AndrewsEnginelab]

Hmmm thanks for checking my post out I know its a buncha random  I want to eventually add some DIY posts maybe videos on the things I am planning on doing... Right now I have my rear brake pedal assembly off and in pieces as i fix a broken weld... My neighbor is very skilled with a welder and Me not so much... so obviously getting him to do it  ... He has already rebuilt his bike  a 1970 honda... he is letting me borrow his Paint booth along with his nice spray gun... I am also stealing his exhaust color... Just looks sweet... He did a damn nice job on his bike Ill post a pic of his up...

Currently I am shopping around for a new signal generator and new handle bars...and a new throttle tube which is expensive... OEM and comes with a grip already on it... have not decided what I want to do about that... 

I lost my gas tank key cleaning up my garage like a dumbass I am going to hold out on buying a new 22$ gas cap until I am 100% sure I will never see that key again.... ughhh 

its to cold to paint my tank and plastics ...  I am going to begin the shitty part of cleaning all the dirt and crud off my bike.... from other people obviously  .. I wont get to anal but I also would like it to look atleast somewhat nice...

I want to put some colorful fuel lines on it... Don't ask I just think they look neat...

Handlebars,brake lever,bar end weights, throttle tube....and perhaps some new grips will be my next buy along with a K&N
also I am looking for a cheap ignition switch... I figure another 250$ and I can have this bike to a point where I will be happy riding it... and it will be mine.... I need to fix the bar height... I,m 6,5 so I wouldn't mind another 2inch of rise.. or so ...

Picking colors is HARD!

[Higgins13]

Hey Higgins I will actually be living in Barrie for the next four years while I do my Bachelor science Nursing we can definitely meet up and ride sometime. Also lemme know what kind of parts you have... I am currently looking for fair amount of smaller things... just found out today my throttle tube has a big crack in it and needs replaced I would say... broken throttle anything sounds like a bad time....



I don't mind this bike so much... Its not a gsxr1000 or R6 but it also didn't cost me 7000$

I will paint the plastics in the spring along with the tank...and the exhaust is getting done in the next week or two....almost a bronze color... looks sweet... I put a bunch of cool pics of things ive worked on over the years...and a few of the bike checkkk it out!  

http://s1205.beta.photobucket.com/

I have full exhaust, turn signals, airbox and filter, older chain and sprockets.

Also once your in Barrie if you see this guy riding around you know it's me :p
http://gstwins.com/gsboard/index.php?topic=62193.0

[Gs500+AndrewsEnginelab]

 .... I found a little crack at the tail end of my pipes and.. even worse! I took my signal generator off today... I already knew it was bent but now it seems my Right hand crankshaft seal is leaking oil and I cannnt really tell but it kinda looks like the tip of my crankshaft is fudging bent!    god damn ... so... I know the bike runs... I have ridden it.... not very fast mind you... my neighbor said it felt kinda slow.... I wouldn't know the difference... So now I have a screwed up signal generator rotor with a noticeable bend the magnets behind the points have exploded into pieces and now i think the crank might be bent... I would say what do i do... but I kinda already know

Either I try and fix the rotor/buy a new rotor/points try that.... see how things goes... if attaching the exhaust correctly and putting a new points gene on it doesn't increase the power.... I will be a little stuck on what to check next...! That's not what I wanted to see....

[Gs500+AndrewsEnginelab]

The Idea of having a bent crankshaft has my mind racing.... Rebuild or find a used... if the cranks bent enough to be causing the oil leak then i doubt a new seal will solve my ever increasing problem!..... Lets hear ideas! 

[Funderb]

you need to post some pics dude.