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Well I just took it for a quick run with the air filter removed. Learned 2 things:
1. God Damn it sounds good a full throttle without an air filter
2. No 6k dead spot at all.

This now sounds exactly what Herenow was seeing as well in the original post. It would then make sense that I am normally running too rich at WOT with the air filter in, and so should lean out the mixture/needle.
The next problem is I've already had the needle at the leanest setting, and still had a big 6k stumble.
I'm wondering if this HiFlo air filter is more restrictive than a stock one would be, so it can't suck enough air with this filter. Has anyone used these OEM replacement filters?
2
I helped the original poster replace fork seals on these forks. I've spent the last hour or so comparing parts diagrams and searching the forums in an effort to learn the differences between the "early" and "newer" forks.

Turns out, the forks in question here appear to be later-style forks, based on the internal damper being the "new" (ie, difficult to get a tool onto) style. (reference, http://gstwins.com/gsboard/index.php?topic=60898.msg704006#msg704006)

Please correct me if I'm wrong about any of the following:

  • All forks for the entire GS500 series are 37mm
  • All forks from any GS500 will physically fit onto any other GS500
  • I don't know what's different internally between early/newer forks
  • "early" refers to 1989-2002
  • "newer" refers to 2003+
  • The part number for the steering stem assembly (aka lower triple) is the same across all model years (and market regions)
  • The pn for the steering head (aka upper triple) is different starting with "later" forks
  • "later" fork lowers have a "protector" (for mud/rocks?) in the area of the fork seal

(note: My determinations regarding part numbers comes from the parts diagrams and the "where used" functionality found on suzukipartshouse.com and takes into account parts that have been deprecated and superceeded. I have no personal affiliation with that website, but I like it for parts diagrams.)

So... Does the original poster need "newer" fork caps?
Will "early" fork caps work?
What's the difference between early/newer fork caps? The ones the OP has are preload-adjustable. Are those the "newer" fork caps, or are they something from an aftermarket supplier?
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General GS500 Discussion / Re: Hypothetical next bike after the GS...
« Last post by TundraOG on Today at 03:50:57 AM »
From what I've come to know, the GS is set up differently around the world for different emission standards. In the US for example it's tuned too lean and people advise a rejet to get it running properly. Here in Israel it's probably tuned differently, plus I put a small windscreen that helps reduce drag substantiality and fit quality radial tires on it. IDK how it got there, it usually doesn't go past 180, maybe the road wasn't as flat as I thought.
4
The caps I currently have are not original to the bike. Iím looking for a set to fit a more traditional style handlebar.

yes I have a pair of caps [well I gotta dig for the OTHER cap] off a 1995 set of forks. just want to make sure that's what you're looking for.
5
The caps I currently have are not original to the bike. Iím looking for a set to fit a more traditional style handlebar.
6
I understand the pilot doesn't directly affect the 6K/WOT issue. I just had 2 seperate issues, so was clarifying that one seems to be under control now (the idle/low load problem).
I'm going to try running without the air filter this arvo and see how it goes.
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General GS500 Discussion / Re: Hypothetical next bike after the GS...
« Last post by MaxD on Today at 01:08:56 AM »
Tundra, I've seen the GS500 top speed reported from 95 to 112 MPH, as a function of faired / unfaired, mods and tuning, and size of and ability of the rider to tuck in.  A large rider makes a real difference here both as to weight and the wind drag they impose, as a big rider could be over twice the weight and have nearly twice the frontal area of a small one.  However, I've seen no other report of any rider getting 195kph = 121MPH out of a GS500 on level ground.  I suspect error in the GPS--mine is often 200 meters off in reporting position.  Another possibility is the wind, as a 10MPH tailwind could add about 7 MPH to top speed.  So, some combination of GPS error, rider size, wind, and slight downhill grade could explain it, just as having those factors working against you might explain 95MPH.       

Here is a video illustrating top speed of a GS500E, which if accurate is probably a small rider that is fully tucked.  It shows 173 kph = 107.5MPH at 9500 rpm.  The engine won't go any faster as it has reached a balance with increasing wind drag and declining horsepower at the very high end of the RPM range. 

https://video.search.yahoo.com/search/video?fr=yfp-t&p=GS500+top+speed#id=3&vid=5448923dbdd3ae3bd9f1223961c748e6&action=click
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the fork caps for the 1993 year? or the newer ones?
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Hi everyone, I have a 1993 GS500E, Lizzie, and Iím replacing her handlebars. I realized several days into the project that my pre-load adjustable top caps wonít work with the new bars. Does anyone in the Seattle area have a set of standard 37mm available?

Thanks in advance!
Ashley
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For Sale / For Trade / Wanted / Hot Deals / ISO:ENGINE
« Last post by Boomerskeeper on September 25, 2018, 08:49:25 PM »
Giving this a shot...searching for a running engine for a 2000 GS500E.  I am located in Southwestern Ontario so hoping and praying someone in this area.  Thanks for your time.
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