Bike died on the highway

[MoodyGs]

Well, first things first hello all. This isn't how I saw my first post taking place but,  while riding to work this morning on my bike (2002 gs500e 8200 miles) i was going about 65-70 mph on the highway.
All of a sudden it started hesitating and quickly died! So I pulled over to the side of the road and checked to see if I had ran out of gas I saw gas in the tank. This is my first bike and I put it on the road on wensday. I turned the bike to reserve just to see if maybe the fuel level was to low. The bike started back up but wouldn't hold an idle. I was 3 exits from work so I got off the highway and limped it to work. Now on the way there it was hesitating back firing and dying at stops. I even pulled over and put gas in it. The symptoms didn't go away! Now I'm sitting at work wondering how I'm going to get home an where even to begin tackling the problem. Any suggestions I would truly appreciate it.

[Blueoval78]

Try running on prime setting on the way home.  Sounds like a problem with your petcock.

[mr72]

This is EXACTLY how mine behaved when it had bent valves.

Does it start and run ok when cold? Does it consistently begin to act up like this after running for 10-15 minutes? Does it seem to only want to run when you rev the snot out of it, like 6K+ rpm?

Anyway, if this is your problem, like my problem, start with checking the valve clearances and ensure they are good. Then maybe try to decarbonize the valves in case they are not closing fully due to carbon buildup. Then come back here if that doesn't work.

Of course there are a dozen other things that might cause your behavior. Vacuum leak preventing sufficient vacuum to hold the petcock, but switching to PRI should fix that (temporarily), sticking float needle would definitely do something like this, low float level, clogged pilot jet, etc. That's all the stuff I fixed before finally getting a top end rebuild.

[Watcher]

My bike would do this fairly often, and would have to sit for several minutes to behave properly.  Problem was a clogged/restrictive fuel filter.

Would only really be an issue if I was on the highway since I was using more fuel than it could flow and I'd drain the bowls.  But it would shudder and lose power then die, and I'd be stuck there for a bit, even on prime.

[ajensen]

It is highly unlikely that you would have bent a valve unless you over-revved the engine. My guess is that the problem is the petcock. When I go 80 mph or so for a while, the same thing happens to my GS500f. When I put it on prime, the problem goes away. Also, make sure your fuel lines are on the correct way. Please let us know how it turns out.

[Watcher]

Troubleshooting 101 is "start with the cheapest solution and work your way up", check the filter/lines first, then petcock, then carbs, then valves.

[MoodyGs]

Alright so I ran out on my lunch break and started the bike. It was idling low with full choke around 1100 rpm. The exhaust smoke was white and smelled heavily of fuel. Got it up to temp and it idled fine. But while riding it's still hesitating and bucking like the power comes and goes.

Ps.
I put it on prime and it ran a tad bit better but still had all the above symptoms.

[Bluesmudge]

If the bike is doing okay at idle it sounds to me like your bike is not getting enough fuel at higher RPMs.
Maybe one of the main jets in your carburetor is clogged?
Is the inside of your tank rust-free?

Fuel filter is another possibility if you have one (there isn't one stock but a lot of bikes have them added). If prime didn't fix the problem then its not your petcock.

[MoodyGs]

No the inside of the tank is a little rusty. But the bike does have a fuel filter after the petcock. I'm hoping I can limp this bike home smh.

[Bluesmudge]

Rust from the tank has likely clogged your fuel filter. Not completely clogged but enough that your bike isn't getting enough fuel above idle.  Most auto parts stores or hardware stores should carry something similar for lawnmowers. Just swap it out with a new one, they are only a couple bucks. Buy a few extra because this will happen again if your tank is rusty.

Those fuel filters clog easily and can be annoying but it may have saved you from having to clean your carbs.

[MoodyGs]

I'm hoping that's the case I'm gonna try to shoot to one the auto parts stores and seeing if that works. I get out of work in 12 mins I'm chomping at the bit.

[Watcher]

I do away with the in-line filters all together.  There is a screen in the tank, any rust that makes it past that won't cause much harm to the carbs.  In fact, any rust that makes it past that would definitely ruin the frame petcock before it ruins anything in the carbs, yet there's no filter between the tank and frame petcock...

Just get a new piece of fuel line and run it straight from the petcock to the carbs and never look back.

[sledge]

If the inside of the tank is rusty the first thing that will clog up is the mesh on the internal side of the under tank fuel valve.

You need to start there and work down towards the carbs.



The white part is the filter mesh, it sits inside the tank and not visible until the valve is removed. Any particles large enough to clog an after market inline filter will clog this filter first 

[The Buddha]

I'm thinking more along the lines of a piece of rust flake holding the float open and not letting it close.
Cool.
Buddha.

[MoodyGs]

Thanks for all the advice guys. During the weekend I pulled the carbs and cleaned them out. I have just bought the bike and imagine my surprise when I find everything including the gas tank was finger tight. And on of my carbs somehow managed to blow a jet off. I'm guessing that was my problem. All the jets were loose not even finger tight just in there jiggling. I cleaned and tighted everything up and reinstalled. Runs way better now then when I bought it.