Discussion: Keihin Carbs, TPS, CDI/ECU, Pulse Gen, Clutch Side Cover

[2005GS500CAFE]

Hi everyone,

I am new to the group and am truly grateful for any help on the following: Keihin Carbs, TPS, CDI/ECU, Pulse Gen, Clutch Cover. I also apologize in advance if this has been answered already but I was unable to find anything.

I am doing a cafe build on a 2005 GS500F with M-Unit & button, Motone switches, relocated choke, Shorai lithium battery, and all electronics  & wiring hidden on a tray under a hump seat.

I would like to put in Keihin 33mm carbs but ran into a problem ... 2004+ GS500's have a TPS setup and the Keihin's don't. Since I am redoing the entire wiring anyway I don't think this is a huge deal. My understanding is that I would have to get say:

1) a 2001-2002 Ignitor Assembly (PART: 32900-01D10)
2) a 2001-2002 Signal Generator (PART: 33110-44420)
3) a 2001-2002 Rotor Comp (PART: 33120-01D10) 

BUT ...

A) will the 2001-2002 Signal Generator fit on my 2005 Clutch Side Cover? Do the bolts lineup?   
B) If the signal gen won't work on my side cover, will getting a 2001-2002 Clutch Side Cover fix the issue? Will the 2001-2002 cover fit my 2005 engine?
C) Do I need a 2001-2002 Rotor Comp or will my 2005 one work on a 2001-2002 Signal Generator?
D) This whole idea was sparked because I stupidly took off the TPS from my carbs and think it will be a nightmare to get tuned correctly. That and needing to rebuild the carbs anyway, I figured, might as well upgrade the carbs. Is all of this insane? Should I reconsider all of this?

Thank you all so much. I will be more than happy to share my experience with the M-UNIT and anything else that pops up during the build. Still to do: revival cycle brake lines, mount up my new exhaust, weld custom tail section, and still deciding about a 06 GSXR front end swap and rear sets .... hmmm. Running out of time and money tho.   

- Alex 

[The Buddha]

Sorry you're trying to fit a what signal generator onto what cover

These carbs don't have no TPS. You have some garbage, you can easily bypass it.

Don't have a clue what you're trying to do.

You can get the 05 carbs working without the tps just fine.
The Keihien swap is likely to be far far far far more work.

Signal generator - you need the 05 one or atleast the 04-09 one 89-00 or 01-02 wont work. Some weird crap like tach etc etc are sensed off that.

Cover - all round covers are equal. Inside cover - its a huge job to swap it, and besides, you need the 04-09 signal plate anyway.

You want carbs without TPS, you better off with 01-02 carb rack, I have one on my 95 and its a breeze to fit, setup and tune ... failing that an 89-00 carb set works just as well.

Cool.
Buddha.

[2005GS500CAFE]

Sorry this was confusing ... still a bit unsure of the terminology. 

I have a 2005 which runs on a TPS system. I would like to put in Keihin Carbs but they are not made with a TPS.

Essentially, I'm trying to make my 2005 work without a TPS, which based on the two wiring diagrams (2005 and 2001-2002, which doesn't have a TPS) I think means getting a 2001-2002 signal generator, 2001-2002 CDI, maybe a 2001-2002 engine side cover in order to mount the signal generator, and maybe the corresponding rotor with the notches that sits in the middle of the signal generator.

Does this all sound right to you?

DIAGRAM: http://www.bikebandit.com/oem-parts/2002-suzuki-gs500/o/m22461#sch234117

Thanks so much,

Alex

[lucas]

The mounting holes are the same, just get the 01-02 signal gen and cdi and you should be good.

If the holehoses were different you could just drill new ones in the signal generator plate.

Check that the signal generator rotor is the same

What is an m unit?

[Big Rich]

Here ya go Lucas: http://motogadget.com/en/electrics/electronic-control-box-m-unit/m-unit-digit-tastersteuerung-u-sicherung.html

An electronic brain for a bike..... that's as much as I know. I don't work with such "high tech voodoo". Haha.

[mwe]

I dont think that m-unit is much of a brain.  From what i can see it looks like a some sort of solid state breaker that replaces the fuse block.

As for the keihins.  i posted a link to an auction in the for/sale section the other day.  i think the buy it now was around 400, I dont do much ebay searching for twin carbs (just stumbled upon it) but that seems somewhat steep for a set of used carbs...i would say it was a fair price if it was a rack of 4 (inline 4 ), but who knows since those carbs work on triumphs and those fellas like to spend money.  You may need to fiddle with the jetting so put aside another $25-50 for various needles and jets and perhaps another $50 for the K/N filters (specific to the CR carbs so that the jets are isolated ...you will not be able to get away with the generic shaZam! pod filters that your cafe brethren typically run)...Otherwise they should be plug and play and should be an improvement over the stock units.

I am not familiar with the TPS carbs (I have a beater 1990 gs500e) but if necessary I dont see any reason why you cant just swap over the ignition system from an earlier model without the TPS

As for the specific parts compatibility, I think that all of the parts posted are compatible across the entire 30 year product line. 

Are you insane....we have yet to see this machine so i cant say.  I will say that if you go the K&N route your carbs will likely be worth anywhere from 25-50% of the machines value...assuming you are not some hack with a rattle can...in which case the carbs will quickly be worth more than the bike.  Good luck.

[mwe]

one more thing.  If you have basic mechanical or really any basic skill set and patience, then the carbs are really not that hard.  Moreover, if you are going the keihin route due to fear of the stock carbs, then I would you suggest you reconsider the hobby altogether (at least the building and wrenching on bikes)....besides at this point what do you have to lose...it sounds like the carbs are off the bike and will end up in the bin if you dont use them so just go for it.

When rebuilding carbs I like to drop them in a vat of 50/50 pinesol and water for a day then clean, rinse and move to a 25/75 vinegar and water solution in a plastic container and I bungee cord the palm sander to the lid and let her rip for another hour (cheap homebrew ultrasonic cleaner).  At this point carbs should be clean...now just go about replacing all the gaskets and o-rings that you get in most kits.

[The Buddha]

Sorry this was confusing ... still a bit unsure of the terminology. 

I have a 2005 which runs on a TPS system. I would like to put in Keihin Carbs but they are not made with a TPS.

No It does not.
Your carb runs off a cable. Anything you hook that cable to works the same.
04-09 carbs are a drop in fit. Otherwise 01-02 is a good second option. Else 89-00.
Keihein is the wrong way to go.
Cool.
Buddha.

[2005GS500CAFE]

Thanks for all the replies, everyone. I will likely just go with the stock carbs and get the TPS back in the right position. Wasn't out of fear but having the TPS already off the carbs seemed like a good time for the Keihin upgrade I was considering.

[The Buddha]

Keihein's an upgrade hardly.
I'd rate mikuni's as far better carbs under most circumstances.
Cool.
Buddha.

[Weedy64]

TPS does exist on F models.

The TPS is used for emission reasons on 04+ F-models.  If you do a TPS or emissions search on this forum you can read descriptions and how it can  be neutered (disabled).  Keihin vs Mikuni I have no opinion really but most peeps on here run Mikuni so jetting advice will be easier to come by.