Updates on my '94 GS500

[geS500]

So as some of you may know I got my very first bike a few months ago! It had a few problems, I had issues with the carburetor my left cylinder would only fire above 5k rpm. As I tore into my it I found out the left carb was missing the entire carb spring/needle! $10 and some trial and error she was running great!

Next task is my current one, I had a small oil leak on the clutch cover, After scraping a 19 y/o gasket for two hours yesterday I'm ready to put her back together today!

In my carb work I also found out I am missing the entire airbox, Do you think I should pick up a used one or just throw a lunch box on there?

So after about two months I have to say I'm still happy with my purchase I don't think I could have gotten a better deal on a bike!

'94 GS500 12,000 Miles!

PS.I bought it this color, It is not here to stay

[X-ray]

Do you know what your jet sizes are? If the previous owner messed up the carbs that badly I would check. It might already be jetted richer to use a lunch box but  then again a stock air box and filter would probably be cheaper.

[geS500]

I really know nothing about the jets, How would I tell?

[radodrill]

The sizes are stamped on the bottom or side of the jets

BTW, are you saying there was no air filter when you bought it?

[X-ray]

Did you go through the sticky about carbs above? Is very useful to get introduced to carbs. I just happened to have mine off so...

Here's a pic of the carb with the float and float needle removed.


These are the jets removed. Notice the stamped in numbers.


There is alot of useful info on the wiki about carb tuning and your set up. Btw The Buddha is the resident expert on carbs and makes rounds regularly.

[geS500]

Yeah I used the thread to figure out what I was missing. ( I'm completely new to working on any type of engine )
I cleaned the jets but paid no attention to the numbers on them, I'll have a look next time i am into them.
Today while putting the crank case cover back on I broke a bolt inside the front cover (one of the two bolts under the Suzuki emblem plate after removing the piece with the wires connected to it) I'm hoping it will work with just one for now until I can get a new one.
I think I got it back together alright, If it is normal to be able to see the gasket all the way around on the outside?

[NikonAndy]

You'll want to easy out that bolt and replace it. With heat and movement from the engine running, that spot will leak for sure if it's not tightened down. Not a ton, but enough to drip and potentially cause warping to the cover's gasket mating surface.

edit:Just realized you meant inside the cover, not the one below around the perimeter of the case. I'd be careful with that, you want to keep that internal area clear of oil and moisture and those two bolts are pretty important in keeping pressure on the gasket and oil out. Better to do that now than risk it, I'd say.

[X-ray]

+1

[geS500]

Now I go to take my oil filter out & I can't get to it, I've tried to come at it from every way. ):
Any tips for doing this?

http://www.gstwin.com/oil_change.htm
I tried using this post it just isn't that simple to get to the bolts.
If I did somehow get the bolts out I don't know how in the world I'd get the actual filter out.

[geS500]

And I bought the new bolt to go in but the old one is stuck in
I have no idea how to get it out

[geS500]

Another oil filter pic

[RossLH]

If it's that bad, just pull the headers off. In my experience, even if you can get the cover off, the V&H headers don't allow enough space to remove the filter.

[X-ray]

Did you break the bolt tightening it, and where on the bolt did it break? With the head broken off there should be no pressure on the bolt any longer and should turn unless possibly it was cross threaded. If you haven't tried already, you may have to take off the cover again to give you access to the stub that may be sticking out. If the bolt broke further down into the threaded hole in the case things are gonna get interesting.

[adidasguy]

Oil cover? Take your flat wrench and remove the 3 nuts. Take cover off. Remove filter.
I have V&H on Junior and change oil easily without removing the exhaust.
There's room. I haven't seen the need to remove the exhaust for any oil change on my bikes or anyone's that's been to the Bike Cave.

[RossLH]

I have V&H on Junior and change oil easily without removing the exhaust.
There's room. I haven't seen the need to remove the exhaust for any oil change on my bikes or anyone's that's been to the Bike Cave.

I've been told this, but there's just no such space on my bike. I have to see a video of it being done to believe it.

[adidasguy]

In your pix I see LOTS of room to remove the oil filter cover.
Take that off then you'll see the filter can easily be taken out.
Just try it. I'll wait...............

[RossLH]

I have tried it on more than one occasion. The cover comes right off, but it's too tight of a space to pull the filter out. No matter which direction I try to remove it, the filter interferes with the engine and the headers. I know I'm not crazy, I have witnesses that watched me try and fail to remove the filter without moving the exhaust.

Though on another note, I just went into the garage to look at the dimensions and found my "missing" exhaust bolt sitting on the headers right under the oil filter cover.

[The Buddha]

V&H wont let you pull the filter - that is well known. That's cos I believe they make the same header for the EX500 too.
Cool.
Buddha.

[adidasguy]

V&H wont let you pull the filter - that is well known. That's cos I believe they make the same header for the EX500 too.
Cool.
Buddha.

Gee, I didn't know that! I must be doing it all wrong by changing the oil filter WITHOUT removing the exhaust.
If everyone knows V&H won't let me do that, am I in trouble for leaving the exhaust on when I change the oil filter?
maybe someone can show me why it can't be done so I can stop changing the filter without removing the exhaust and start doing it by removing the exhaust.

[gsJack]

Your Limey buddy will probably be around to straighten you out.