Stuck Floats, Gas in Oil, Sad Owner

[Turkey]

Hi All,

I've been running into the same issue on my 2007 GS500f a number of times now. A couple years ago I got stranded while riding with the bike shutting off and gas dripping out of my airbox drain hose. It seemed to be a stuck float and I opened up the carbs and cleaned them out and changed the oil (which had gas in it from the overflow). That seemed to fix the problem, but abut a week later, same problem. This time I changed the oil, cleaned the carbs, and also completely replaced the needles, their housings, and a number of gaskets. I also added a fuel filter to the main fuel line (but not the reserve) to make sure I wasn't any getting sediment from my tank into the floats. All was good for about a year, but this March it happened again. I changed the oil and cleaned the carbs and all was good until today. Today I was about to take a short ride around town and I saw a puddle of gas under the bike and smelled gas in the oil, the same reoccurring problem. The bike is not on the Prime setting on the petcock for reference. My last ride was a week ago, a problem free 40 miles or so, so I was surprised to see there was a puddle of gas under the bike. When I tried to start it, it was shaking, and died off quickly, with more gas soon dripping out of the airbox.

Does anyone have any thoughts on why this could be a repeat problem? Between the new needles, clean carbs, and fuel filter, I'm not sure what else I can do. I'm getting pretty sick of changing my oil as well. Each time this happens I've run carb cleaner and guitar string through the jets, and degunked the carbs (they appear to be pretty clean, although I haven't opened them up yet this time).

Thanks in advance.

[ShowBizWolf]

I had that problem ONCE and it was enough!! I can only imagine the frustration of having it occur several times

Only thing I can think of is, have you replaced the frame petcock with a new one? It should be stopping the fuel there. It was one of the first repairs I had to do on my GS. But then again, even if it is failing, the carbs should stop the fuel from going into the oil....

I am sending best wishes to you, getting it sorted finally. What an awful repeat problem to have

[Meukowi]

yea, same come up to my mind, maybe the petcock is broken and stuck on prime?
Not too many possible faults, gas comes from tank to float chamber, and the needle keeps it from overflowing, only the petcock is regulating the movement  between.

[The Buddha]

IMHO Suzuki with the new 3 jet design carbs fixed carbs that worked just fine to carbs that crap out all the time.
The float seat has O ring and the rubber stopper goes into the metal seat. Those all have to fit right to each other and seal up.
Put it together and blow into the fuel inlet with the carbs upside down. It should hold up your lung power.
That's a way to test it outside the bike.
BTW you route the hoses and connect up right ? You have fuel inlet going into the lower T not the upper T right ?
Cool.
Buddha.

[Turkey]

Thanks all for the comments thus far.

I can give a petcock replacement a try. The petcock does work for at least changing to the reserve tank (I ran out of gas a couple weeks ago, and changed it over to reserve and it worked just fine), but there could be some weird issue between prime and the normal down position.

I believe I have the houses connected properly, although I can double check.