Really Rough Shifting + Possible electrical issues?

[lynx124]

side stand switch? 

The GS uses oil -at least most of them can eat up to 1 quart every 500 miles.  This is why it is so important to check the oil all the time.  Just make it part of your start up routine when you start your day.

And by the way, your mega paragraph made my eyes bleed.  But it's OK.  We are an accepting bunch.

HAHA, again im SO sorry for the mega paragraph, it WONT happen again.

Im beginning to think that it IS the side-stand switch, because looking back, every time the engine stopped on me, i was coming out of a LEFT turn...the same side as the sidestand...The unfortunate bit is that I have NO CLUE where to even begin inspecting/fixing/replacing this stuff...can some one link a tutorial or something to me.

This is the first major issue ive had with this bike so I have yet to order a manual...Im gonna do it now, but Id rather not wait until it arrives before I start fixing this...The weather this week is beautiful and im just ITCHING to ride! and of course riding my dad's cruise is a big no-no...so yea...maybe its because its a 900lbs 1100cc and im 144lbs...o well 

[gsJack]

The clutch is properly adjust from the lever end, I can assure you that. I didnt follow any links, I just found the adjustment mechanism similar to dirt bike ones.
I did learn, however that apparently there is one or two more adjustment point and yea...i have no clue where to begin with finding and checking those.

Make a complete 3 point clutch adjustment to get it setup proper to start.  It's important to get the pushrod freeplay right to get proper clutch action.  After that minor freeplay adjustments can be made at the clutch lever adjustment.  From Suzuki Shop Manual:  http://www.gs500.net/gallery/data/500/GS500_clutch_adjustment1.jpg

[lynx124]

Thank you, Ill adjust it properly tonight!

[Snake2715]

Just like you had not properly adjusted the clutch how did you adjust the chain slack?

One tick from center tells nothing as we know nothing about how your specific chain has worn and or stretched.

The suzuki swingarm marks are also known to be off from one side to another so maybe the wheel is crooked.

http://cgi.stanford.edu/~sanjayd/gs500/Maintenance/AdjustChainTension


Remember that when you sit down on the bike the chain gets tighter as well.

This is not to demean you in anyway, just want to make sure its been done correctly.

Here is another couple thread on chains:

http://gstwins.com/gsboard/index.php?topic=56181.0

[lynx124]

Just like you had not properly adjusted the clutch how did you adjust the chain slack?

One tick from center tells nothing as we know nothing about how your specific chain has worn and or stretched.

The suzuki swingarm marks are also known to be off from one side to another so maybe the wheel is crooked.

http://cgi.stanford.edu/~sanjayd/gs500/Maintenance/AdjustChainTension


Remember that when you sit down on the bike the chain gets tighter as well.

This is not to demean you in anyway, just want to make sure its been done correctly.

Here is another couple thread on chains:

http://gstwins.com/gsboard/index.php?topic=56181.0

No I know ur not being demeaning, thank you. This is good stuff that I need to learn! So as far as the chain tension it is proper (1" of play), however I am willing to re-adjust the whole thing tomorrow just for the sake of assurance and practice. Afterall, it is a skill i will need to master anyways.

The bike is still a baby (under 7K mi) and it was never ridden too hard so a crooked wheel seems really unlikely.

[lynx124]

Ok so after running the bike on the center stand and fiddling with the side stand I'm 95% sure that the issues I'm having is due to a faulty safety switch. I DO NOT want to bypass it because it's a safety feature and it's there for good reason. I do, however, want to fix/replace it. Any guidance in the proper direction will be EXTREMELY appreciated...

I'm just glad I'm done with the diagnosis and the prognosis looks positive...sorry...3rd year pre-med student creepin out

[Janx101]

I'm glad for you that it is working out... dunno tech specs of side stand switch .. but i would check for loose wires, loose mount/switch etc

...

.. totally amazed that it didnt turn out to be starved of oil, run dry and overheated!! ..   

[BockinBboy]

Note on the hard shifting... The topic has been beaten on this forum to only mention it in this case... As I understand the oil was just recently changed, correct?

If the oil level is too high, it is tough to shift and find neutral. Refer to the manual or quotes from the manual found on the forum on how to properly check oil level.



- Bboy

[Janx101]

thats a cool point Bocky ... not one that i consciously remember seeing... but yeah makes sense.. too high oil is bad for other reasons than too low oil... 

[gsatterw]

Same guy, huh? I owe him ALOT of thank you's starting with the fact that he taught a 5'10'' 144lbs guy like me how to put the bike on the centerstand without any help lol

[sledge]

UPDATE:

I took it out for a quick spin and it stopped AGAIN in SECOND GEAR! 

I am struggling to pick out the relevant parts but........

Is it ONLY doing this when 2nd is selected?......and when it does stop does it stop dead?........Will the engine run with the other gears selected?

The F`s use a more advanced (and complicated) ignition/carb set up then the E`s that includes throttle position sensors and solenoids. I have no first hand experience of this system but believe it also uses a position switch that feeds directly back to and tells the ignition control module when 1st or 2nd is selected.

If as you are saying your bike dies when 2nd is engaged the problem is almost certainly related 

[adidasguy]

I'll have a new video tomorrow. Just finished a rough cut of opening up the left side of the engine to tighten down the magnet rotor/starter gear that came loose on Suzi.

Then I have to finish editing the restoration of Quin where we replaced the rear wheel and chain.

[Paulcet]

As a temporary measure, you can bypass the switch to rule it out: trace the wires back from the switch til you find the connector(s), disconnect and install a jumper wire on the wire harness side.

[lynx124]

Ok thanks for everyone's input! Here's what I ended up doing to test the potential safety switch problem.

I set the bike up on the center stand in my driveway in the sun (warm day) and let it idle at 1.5K rpm for about 15 mins. Then I pulled in the clutch, shifted to first gear, had my brother apply some throttle, and got the back wheel to spin.

I then shook the crap out of the side stand to simulate road vibrations. Up down left right--all of it. And the engine never cut. PLENTY of free play before the engine finally cut. When it did, the "screw" that gets pushed in and closes the circuit when the side stand is up was more than half-way exposed...meaning it really takes a lot before the circuit is re-opened and the engine is killed.

I repeated the above method again, only this time in second gear and I produced similar results.

Lastly I took it out for a ride around my area. I made sharp left u-turns and several circles to the left and the engine never cut.

Now I'm not sure if I should be happy cuz it never cut or upset because I'm back to square one in which I dunno what the hell made it stop in the first place...is the GS known for electrical "flukes"?

Thanks in advance for ur pointers!

[adidasguy]

The switch might be going bad. (I have seen 2 bad side stand switches).
Another possibility (which I have sen) is the pins that hold the springs are bent in a little so the side stand does not stay tight in the up position. Bending the spring holders a little farther apart to provide more tension on the springs might help.

If you think it is the side stand switch, you can short it out at the connector under the seat. if you do hat for a day and you have no more issues then it is the side stand switch or the springs holding the side stand up.

[lynx124]

The switch might be going bad. (I have seen 2 bad side stand switches).
Another possibility (which I have sen) is the pins that hold the springs are bent in a little so the side stand does not stay tight in the up position. Bending the spring holders a little farther apart to provide more tension on the springs might help.

If you think it is the side stand switch, you can short it out at the connector under the seat. if you do hat for a day and you have no more issues then it is the side stand switch or the springs holding the side stand up.

I'm gonna try bending the spring holders like u said and ill also hold the actual "screw" in the bike with some heat resistant tape as to temporarily "short it out" then ill take it out for a nice long ride around town. If it doesn't die on me ill take the tape off and repeat with just the bent holders. If it doesn't die on me then, I'm good. If it does ill probably by a new switch and install it.

I really really really do not want to permanently bypass the safety as I am a fairly new rider and I need all the safety I can get. Also, my brother, (16yo) is eager to join my dad and I on the saddle so I'd love to give him my bike as his starter. Being that he's my brother I think it is only right to give him all the safety he can get---even if it's the silly side stand switch.

Thanks for the idea of bending the holders tho! I didn't think of that.

PS if you can reply with a YouTube link of the video you were talking about earlier it would be really appreciated. Your videos are frikin awesome (ESP for me--very visual learner--so the service manual sometimes doesn't cut it!)

[adidasguy]

Video link is in the video sticky thread.

[lynx124]

Video link is in the video sticky thread.

Thank you!
Sorry still newbie in the forum!

[Electrojake]

I went and looked at the bike and its fine. No gearcase horrors, etc...
BTW: His spotless super-sized Honda Shadow parked next to the GS makes the GS500F look tiny in comparison.

Seems the only issue the GS has is that twice (and only twice) the engine completely cut-out while leaning to the left at low speed.
A total loss of power just as you expect to lean on the throttle and pull into traffic is Unacceptable.

So...
Off with the fairings, tank, & seat till we find the true meaning of "intermittent malfunction".
As mentioned here earlier, I too am suspecting something to do with the primary ignition system (and/or various switches) since both cylinders instantly die and then recover fine.

Photos and an explanation of what we found will follow in about ten days. 
-Ej-

[lynx124]

I went and looked at the bike and its fine. No gearcase horrors, etc...
BTW: His spotless super-sized Honda Shadow parked next to the GS makes the GS500F look tiny in comparison.

Seems the only issue the GS has is that twice (and only twice) the engine completely cut-out while leaning to the left at low speed.
A total loss of power just as you expect to lean on the throttle and pull into traffic is Unacceptable.

So...
Off with the fairings, tank, & seat till we find the true meaning of "intermittent malfunction".
As mentioned here earlier, I too am suspecting something to do with the primary ignition system (and/or various switches) since both cylinders instantly die and then recover fine.

Photos and an explanation of what we found will follow in about ten days. 
-Ej-

Thanks again for stopping by! I really appreciate you taking time out to help me with this. I can't wait for those tires to get Rollin again!😈