GStwin.com GS500 Message Forum

So I started a previous thread, but I've moved way past that problem and into a whole new mess.  After inspecting my carbs I realized I need to do a re-build.  So I cleaned off what I could and re-assembled the carbs.  Both small o-ring seals on the carbs were missing when I opened them up.  I'm also missing a couple hoses... one off the bottom of my airbox, the "drain hose" I think (anyone know where that one connects to?) and another on the carb (the one coming off of the upper T fitting, oh man, wish I had a digital camera).  So anyhow, before I discovered all this, the bike ran, but would idle really high (4000rpm) after warming up.  Hence, I took out the carbs to find out why it was running lean.  Well I put everything back together and started it up figuring it would at least run the way it did before I took it apart.  Well, now it fires up immediatly and shoots to 5000rpms, it smells like something is burning, and smoke is coming out of the bottom of my air filter where the drain hose is supposed to be.  I don't have much money so towing it to a mechanic isn't really an option.  Any help would be greatly appreciated!

Time for a drink!  :cheers:

Sorry, I have no mechanical knowledge whatsoever, but I'm sure somebody more helpful will reply soon.

Laura

First thing I would do is let the bike warm up then adjust the idle to the proper setting, probably around 1,200. Just out of curiosity, what color smoke is it?

Plus check the choke to see that it is all the way disengaged, and I'm not sure if your GS uses CV carbs, but if it does make sure you have both hoses connected from the petcock.

The smoke is white... and I'm pretty sure I've adjusted the idle screw so that it will idle as low as possible.

Like VTNewb said, check to make sure that the choke is entirely OFF.  The carb end of the cable should look like this:
(http://www.bbburma.net/MiscFotos/100_0130_ChokeCableCloseUp.jpg)

If the choke cable looks OK and seems to slide smoothly, move your attention to the throttle cable.  Is it possible that you pinched or misrouted it during reassembly?  It's also easy to adjust the cable too tight when you reassemble it, because of the odd way it attaches to the carbs.  You can try to loosen the cable up a bit using the adjuster on the handlebar end.  (It's right below the brass screw in the photo.)
(http://www.bbburma.net/KodakFotos/ThrottleRetainer/100_0023_PositionThrottleGrip1.jpg)

Meanwhile, the missing O-rings are a problem.  I can't remember - did you already know about the rebuild kits from PartsNMore.com (http://www.partsnmore.net/part_cat.php?make=suzuki&category=carb_kits)?

Thanks for the info.  My choke is okay, it was improvised by the previous owner... there is no cable to the handlebar controls, instead, a zip tie is connected directly to it.  Lame, but it works.  Checked out the rebuild kits.  Parts n more is out of them but I requested to be notified when they come in.  I'm worried I may have replaced some hoses incorrectly.  The bike didn't have a hose coming from the upper t-fitting or from the drain outlet at the bottom of my airbox.

Quote from: ponchopirateI'm also missing a couple hoses... one off the bottom of my airbox, the "drain hose" I think (anyone know where that one connects to?) and another on the carb (the one coming off of the upper T fitting, oh man, wish I had a digital camera).

The airbox drain hose is routed (along with the battery drain hose and 1 or 2 others) so that it comes out near the right footpeg.  It is a fairly large diameter hose, capped on the lower end, with a slit in the cap that you can't really see until you bend it one way or the other.  (Sorry, mine was REALLY dirty when I took the picture.)


The other missing hose just leads to open air, so it may be more desirable than essential.  Its position is fully depicted in the diagram at the bottom of my Fuel Hose Routing page.

The fact that "smoke" is coming out of the airbox drain spout worries me a bit.  That seems to indicate a pretty good flow through the crankcase breather hose - the short fat one that connects to the top front of the airbox.  With that much "blow by" I wonder if you have some worn rings or something.  :dunno:   But I'm just guessing - you'll want to check with a real "engine guy".

im afraid to mess with my carbs cause i dont wanna have to trouble shoot :x

Thanks for the tips and pics, I really appreciate it!  I'm going to check out my throttle cable connection tomorrow and see what happens.  If I don't have any luck I guess I'll just have to take it into the shop  :(  It didn't smoke before I removed the carbs, so I'm hoping it's just related to something stupid I did and not major engine trouble.