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Main Area => General GS500 Discussion => Topic started by: Nedry on June 29, 2012, 04:51:43 PM

Title: 2002 GS5003 problem
Post by: Nedry on June 29, 2012, 04:51:43 PM
topic typo, sorry.   2002 GS500e

Hate to start a new thread, but ive looked around and still cant seem find my exact issue...

Anyway, as mentioned i have a 2002 gs5003 which was running like a top until about a week ago.  I rode up to the American legion, only a mile away or so and all seemed well.  When i left, i encountered a hesitant motor, like it was starved for fuel. It eventually died completely, and I had to just sit for a few, it would restart, and get me another 500 yards or so till i was able to guide her into my garage.

Since then, I have exhauseted my knowledge, and that of a more competent friend of mine to fix it to no avail.

Number 1, the bike is fouling spark plugs bigtime. I realize choking the bike doesnt help with that, but to get it to start now, that is the only way.

2) once it does start, without fail, it WILL die, and not want to restart for some time. It totally feels like its simply dying from being starved of fuel...

3) oil level is fine, air filter is not an issue, and all seems well with that battery (and spark plugs til they get fouled from too many repeated attempts at starting under choke...)

Near as I can tell fuel is getting to the bowls just fine, as when i open them up, fuel flows freely.  It does smell of gas and/flooding something fierce (even from the tailpipe...) but ive no idea why this started happening out of the blue.

it seems to not matter at all whether i run it in 'on',  prime, or reserve, the bike will still die after about 3-5 minutes of smooth idle.

Im at a loss...

any point in a direction i have not looked be appreciated. 

thx in advance.

Title: Re: 2002 GS5003 problem
Post by: Paulcet on June 29, 2012, 05:17:17 PM
Check the fuel level with the clear u-tube method. That would confirm a possible float needle leak or bad o-ring on the needle seat.
Title: Re: 2002 GS5003 problem
Post by: Nedry on June 29, 2012, 06:07:50 PM
ill google that method i guess, as im totally unfamiliar with it....

but if its a carb issue, its outside echelon....

im still holding on to the possibility that the fuel valve may be faulty, but thats just wishful thinking i imagine lol
Title: Re: 2002 GS5003 problem
Post by: Paulcet on June 29, 2012, 07:23:58 PM
At the moment I can only think of one problem with the fuel valve alone that would cause those symptoms. That would be an internal leak through the vacuum diaphragm and down the vacuum hose to the port on the carb.
Title: Re: 2002 GS5003 problem
Post by: Nedry on June 30, 2012, 03:01:03 PM
Thanks Paulcet, thats good info.  I will look into the vacuum diaphragm this weekend if Im able get away from family obligations for a few hours... Hopefully taking the fuel valve apart isnt too much of a chore...
Title: Re: 2002 GS5003 problem
Post by: craigs449 on July 01, 2012, 05:32:56 PM
Sounds like sticking floats, dirty needle valve seats, or float height is set too high.......If you are fouling plugs, you are running rich, not lean......That also explains the strong gas smell and the fact that it won't start well. =rich condition/too much fuel
Title: Re: 2002 GS5003 problem
Post by: twinrat on July 02, 2012, 12:52:31 AM
Sounds like you have a coil on the way out ,or something in the electrical ignition system .Symption it runs till it heats up then dies on you .when it cools enough you can ride on again till it heats up again.check the ignition module ,also pull the electrical plugs arund the bike a couple of times  you may have one thats not fully home .
Title: Re: 2002 GS5003 problem
Post by: bigfatcat on July 03, 2012, 04:09:13 AM
Agree with twinrat ... a failing ignition can cause fuel fouled plugs, gas smell .   May be problem with an intermittently failing safety switch. Or grounds.  Or ignition control module.  etc.
Title: Re: 2002 GS5003 problem
Post by: Nedry on July 03, 2012, 07:06:08 PM
truth be told, i have dumped a signifcant amount of money into this bike for a full valve job, and even had the bores punched out to re-round them... its been a fantastic bike, but now all i really want to do is get it running reliably, so i can selll it for something different.

it has me that frustrated.
Title: Re: 2002 GS5003 problem
Post by: Nedry on July 13, 2012, 05:51:25 PM
Well, with the help of a friend of mine, we were able to bypass the petcock altogether and get constant and reliable fuel flow to the carbs.

I couldnt find a proper rebuild kit, so we went this route.  It now runs like a champ  :)

Now im not inclined to sell it lol.