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Main Area => General GS500 Discussion => Topic started by: salamander on August 09, 2012, 06:17:11 AM

Title: Getting my son's bike running better
Post by: salamander on August 09, 2012, 06:17:11 AM
My son and I have been working on his '95 500E over the summer.  I don't have a lot of experience working on motorcycles beyond routine maintenance, but I'm comfortable with a wrench, and this seemed like a good way to teach him some basic mechanics, get him used to working on his own bike, and have some fun all at the same time.  As we've gone through this, I've posted individual threads, but some of the issues we're still have are starting to look like they're connected, so I thought I'd start a new thread to collect everything in one place.

Here's the back story on the bike.  My wife's brother bought the bike in Denver for my son to ride while he was out there a little over a year ago, and he brought the bike out to us last summer in the back of a pickup.  Unfortunately, we don't know anything about the bike's history before it was bought -- it's obviously been dropped on the right side, so it has a dent in the tank and some scuffs, but otherwise seems sound.  I've only ridden the bike a couple of times to a shop for the state inspection, but it didn't seem to have the acceleration I would have expected.  My son has his learner's permit, and is legal to ride during the daytime, but my wife and I are firm believers in a quick bike is more likely to let you get out of any trouble, so that's where this whole project really started.

Here's what's been done so far:
- cleaned the carburetors and replaced all of the o-rings (except the ones below the slide guides) and the diaphragms
- re-jetted (just for kicks) from stock to 40/140 with one washer and 2.5 turns out on the pilot screws (we just followed the re-jetting table)
- replaced the stock airbox with a lunchbox filter
- replaced the plugs -- the insulator on the left one was almost black and the right was almost new looking

When we put it all back together, it actually started -- we were shocked -- and much more easily than before.  We balanced the carburetors, and it sounds like a whole different bike.  It's much more responsive to the throttle, and doesn't bog down or hang when the throttle is opened/closed.

That's more or less where we are now.  There are still some issues that for me are uncharted waters, and I'll put them in additional posts just to keep things organized.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 06:58:38 AM
The biggest problem we're still seeing at the moment is that we're getting gas in the oil sump.  We had hoped replacing the o-rings, which hardly qualified as o-rings anymore, in the carburetors would stop it, but it hasn't, at least not completely.

We changed the oil and filter, and then I remembered I hadn't checked the float heights when the carburetors were out for the first cleaning.  When I pulled the carburetors, I noticed raw gas in the left intake boot, and down into the intake area of the cylinder head, but only on the left cyclinder, not the right.  All of a sudden the black left plug makes a little more sense.  Turns out the float heights were way off, by 3-4 mm, in both bowls, but maybe a little worse in the left.  Could this have caused gas to overflow into the intakes when the bike was not running?  I think I have them adjusted correctly now, but it may take some time to see if it's fixed the problem.

Any thoughts on anything else I can check while we're waiting to see what effect the float adjustment makes?

Thanks.
Title: Re: Getting my son's bike running better
Post by: RossLH on August 09, 2012, 08:16:13 AM
If the float height is set wrong, the float needle won't cut off fuel. So yes, what you saw is very much an indicator of improper float height. With the carbs back on the bike, you can use the clear tube method to check the float height. Attach a clear tube to the float bowl drain, bend it into a 'U' shape, set the petcock to prime, and open the float bowl drain. The fuel level in the tube should stay below the float bowl gasket.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 09:22:03 AM
Thanks.  It's good to know that floats that far out of whack could cause the problem, and I'm hoping adjusting them may have fixed the problem.  It also occured to me, though, that if the float needles aren't seating completely, they could leak slowly causing the flooding overnight.  Is there a way to check whether the needles are completely sealing off the gas flow?
Title: Re: Getting my son's bike running better
Post by: Dizzledan on August 09, 2012, 09:31:57 AM
The best way to check the needle/seat condition in to pull the carbs, drop the bowls and look. The tip of the float should be a perfect conical shape, it shouldn't have any depressions on the face of the rubber. The orings in the seats will probably need re-done too.
Title: Re: Getting my son's bike running better
Post by: knowles on August 09, 2012, 09:40:35 AM
I didn't see that you do a carb rebuild kit when you had the carbs out. I would consider doing this. also i would check the valves- easy to do and there is a vid on here on how to do it. Also if you rejeted and put a pod air filter i would suggest putting on a different exhaust to make the whole system work better. you have more air and gas, but the same exhaust.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 10:07:45 AM
Quote from: Dizzledan on August 09, 2012, 09:31:57 AM
The best way to check the needle/seat condition in to pull the carbs, drop the bowls and look. The tip of the float should be a perfect conical shape, it shouldn't have any depressions on the face of the rubber. The orings in the seats will probably need re-done too.
Both times I had the carbs out, I checked the condition of the needles and the seats.  The seats show no sign of wear, and the needles have conical tips with no sign of wear by the eyeball method.  The o-ring at the top of the valve seat was replaced in the initial cleaning.  One question, though:  the black, conical tops of the needles are fairly hard, and so far as I was willing to push on them, they really didn't seem to have any give.  Is this just a hard type rubber, or should they softer like, say, an o-ring?

Quote from: knowles
I didn't see that you do a carb rebuild kit when you had the carbs out. I would consider doing this. also i would check the valves- easy to do and there is a vid on here on how to do it. Also if you rejeted and put a pod air filter i would suggest putting on a different exhaust to make the whole system work better. you have more air and gas, but the same exhaust.
I'm not familiar with what's included in the rebuild kits.  I've replaced the o-rings and diaphragm, and cleaned everything else I could.  Are you thinking of some specific part of a kit that I've overlooked?  A different exhaust may be an option for a later time if my son really gets into riding.  Unfortunately, it wasn't until after the air filter and new jets were in did I see some posts about about the lunchbox filter/larger jets/stock exhaust maybe not being optimal.  What would I be looking for as far as checking the valves (sorry, I'm new to really anything other than things like oil changes, plug changes etc)?
Title: Re: Getting my son's bike running better
Post by: RossLH on August 09, 2012, 10:50:34 AM
Rebuild kits typically include a new float needle, float needle seat (w/ o-ring pre-installed), float bowl gasket, float o-ring, and carb cap o-ring.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 11:11:49 AM
Quote from: RossLH on August 09, 2012, 10:50:34 AM
Rebuild kits typically include a new float needle, float needle seat (w/ o-ring pre-installed), float bowl gasket, float o-ring, and carb cap o-ring.
That would have been easier.  I ordered the o-rings and gasket separately, but I'm re-using the float needle and seat (maybe a mistake).  By 'float o-ring' do you mean the one that seals over the long metal opening for the choke circuit?  If not, I may be missing an o-ring entirely -- seems unlikely, but stranger things have happened.

Thanks.
Title: Re: Getting my son's bike running better
Post by: RossLH on August 09, 2012, 11:55:40 AM
I'm talking about the o-ring at the end of the float assembly that seals the choke circuit and holds the float assembly in place.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 12:29:03 PM
Great, we're on the same page.  That one was replaced along with the rest.  Thanks, and sorry for the confusion on my part.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 12:39:02 PM
Here's a miscellaneous sort of thing while I'm waiting to see what happens after the float adjustments.

Because the bike was taken down on the right side sometime in the past, the right footrest rubber is torn just enough to make you uncomfortable as your foot shifts around.  I ordered a replacement, but misread the parts diagram and got the left foortrest  :embarassed:.  Even so, it looks like the rubber part doesn't have a left/right version even though the metal part of the footrest does.  What I'd like to do is put the new left footrest on the bike and use the old one's rubber to replace the torn rubber on ther right one.  Before I start ripping out fingernails trying to get the rubber off, is it even possible to do or are there any tricks to doing it?
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 09, 2012, 02:41:39 PM
Just for the record, the gas level should be even with the float bowl gasket; not above, and not below.

I think you did the right thing not getting a rebuild kit.  The needle valves that come in the aftermarket kits didn't work for me anyway.  New OEM ones worked great.  If you can't get the gas level worked out with your current needle valves, just order a new OEM set.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 02:56:42 PM
Quote from: bombsquad83 on August 09, 2012, 02:41:39 PM
Just for the record, the gas level should be even with the float bowl gasket; not above, and not below.

I think you did the right thing not getting a rebuild kit.  The needle valves that come in the aftermarket kits didn't work for me anyway.  New OEM ones worked great.  If you can't get the gas level worked out with your current needle valves, just order a new OEM set.
After the carbs were pulled the second time for float adjustment, I used the tube attached to the bowl drain method (on the benchtop, not installed on the bike) to confirm what I'd done, and I think I have them darn close to what they should be, and what you describe.

It seems like I pretty much bought a rebuild kit piecewise except for the float needle and seat.  I'm really interested in the float needle at this point, though.  Should the black rubber tip of the needle be sort of like a pencil eraser in terms on 'bendiness' or should it be a hard rubber?  The needles we have now are hard, and until knowles mentioned that they're rubber, I thought they were some sort of composite or ceramic.  At this point, I'm halfway planning to order a pair of needle valves to be safe.

Thanks
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 09, 2012, 03:26:10 PM
It's probably worth your piece of mind to order new ones.  So many fuel in airbox/crankcase posts on this forum its not even funny.
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 03:45:59 PM
As soon as I can convince my wife, who says we're way overbudget :D, that new float needles are necessary, I'm going to order them, or buy them locally if I can find them.  The place I've been ordering parts from only sells the needles and seats as an assembly, but I'm really only interested in the needles.  Does anyone know of a place that sells the needles separate from the seats?

Thanks.
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 09, 2012, 03:53:30 PM
They are sold as a set for a reason.  They ware together (supposedly).
Title: Re: Getting my son's bike running better
Post by: salamander on August 09, 2012, 03:57:58 PM
Doh ... that makes a lot of sense.

Thanks.
Title: Re: Getting my son's bike running better
Post by: salamander on August 10, 2012, 02:25:04 PM
After 2 days, there doesn't seem to be any change in the oil level, so changing the float heights may have done the trick.  We did get some gas in the oil in the bike now, though, so I'm going to change it out again in the next few days to be safe.

Since the last oil change a few days ago, my son has put ~60 miles on the bike and mentioned that he thought the clutch slipped a few times, usually during acceleration -- rpm's suddenly increase but the bike doesn't go with it.  When I did that oil change, I managed to find a filter locally and bought the oil there while I was at it -- a gallon of Kawasaki 10W40, which was all they had.  I looked at the label and it said it was for wet-clutch bikes so I took a chance.  Now, I'm wondering if the new oil could be the reason for the clutch slipping.  The label said it was suitable for API-SL and JASO MA/MA-2 applications.  Should I be looking for something below SL?

Thanks.
Title: Re: Getting my son's bike running better
Post by: iclrag on August 10, 2012, 02:57:28 PM
Quote from: salamander on August 10, 2012, 02:25:04 PM
After 2 days, there doesn't seem to be any change in the oil level, so changing the float heights may have done the trick.  We did get some gas in the oil in the bike now, though, so I'm going to change it out again in the next few days to be safe.

Since the last oil change a few days ago, my son has put ~60 miles on the bike and mentioned that he thought the clutch slipped a few times, usually during acceleration -- rpm's suddenly increase but the bike doesn't go with it.  When I did that oil change, I managed to find a filter locally and bought the oil there while I was at it -- a gallon of Kawasaki 10W40, which was all they had.  I looked at the label and it said it was for wet-clutch bikes so I took a chance.  Now, I'm wondering if the new oil could be the reason for the clutch slipping.  The label said it was suitable for API-SL and JASO MA/MA-2 applications.  Should I be looking for something below SL?

Thanks.
It's a possiblity it's the oil, i forget if you do or don't want wet clutch oil. I stick with the Castrol synthetic motorcycle racing oil, it's usually cheap since it's an older oil (not new technology) but i've used it in every bike i've ever owned.
i've heard good tings about royal purple as well and i may try it the next time i do an oil change
Title: Re: Getting my son's bike running better
Post by: adidasguy on August 10, 2012, 03:05:40 PM
#5271

If for wet clutch, it should be OK.
Try checking your clutch cable adjustment. Maybe it is too tight.
The WIKI has a tutorial on clutch adjustment.

Owners manual says API of SF, SG, SH or SJ
JASO of MA
Not to use "energy conserving" oils or oils with friction modifiers.

Not sure how the Kawasaki oil stands against the Suzuki owners manual. No idea what "SL" or any of the API letters mean. Someone else should know.
Title: Re: Getting my son's bike running better
Post by: iclrag on August 10, 2012, 03:07:43 PM
Quote from: adidasguy on August 10, 2012, 03:05:40 PM
#5271

If for wet clutch, it should be OK.
Try checking your clutch cable adjustment. Maybe it is too tight.
The WIKI has a tutorial on clutch adjustment.

Owners manual says API of SF, SG, SH or SJ
JASO of MA
Not to use "energy conserving" oils or oils with friction modifiers.

Not sure how the Kawasaki oil stands against the Suzuki owners manual. No idea what "SL" or any of the API letters mean. Someone else should know.


For future reference

According to the American Petroleum Institute (API), SL motor oil grade is used in gasoline engines in automotive vehicles made in 2004 or earlier. SJ motor oil is used in gasoline engines made in 2001 or earlier. Both grades can be used in any older car that requires earlier motor oil grades SA through SH.
Title: Re: Getting my son's bike running better
Post by: adidasguy on August 10, 2012, 03:12:12 PM
#5272

I was reading from the GS500F 2008 owners manual. "SL"? Go figure what the manual says. A new 2008 bike specifying SF-SJ.
I vote to check the clutch adjustment.
Title: Re: Getting my son's bike running better
Post by: salamander on August 11, 2012, 04:05:19 PM
Quote from: adidasguy on August 10, 2012, 03:12:12 PM
I vote to check the clutch adjustment.
Only time will tell, along a test drive (but it's raining today, so not likely), but it looks like the clutch adjustment faction wins.  Although the clutch cable play had been adusted before this whole project started, one thing I forget to mention was that all of the fuel lines were replaced during the first go around with the bike, and it's likely the cable is routed a little differently.  When I checked the cable play based on AdidasGuy's suggestion, it was tight with none of the play I had in it before.  It's been readjusted and I'm hoping the slippage problem goes away.

Thanks.

PS: Day 3 with no extra gas in the oil -- I'm about ready to call that problem over.
Title: Re: Getting my son's bike running better
Post by: salamander on August 12, 2012, 07:10:07 AM
Quote from: salamander on August 09, 2012, 12:39:02 PM
What I'd like to do is put the new left footrest on the bike and use the old one's rubber to replace the torn rubber on ther right one.  Before I start ripping out fingernails trying to get the rubber off, is it even possible to do or are there any tricks to doing it?
For what it's worth, I'm going with 'no' it's not possible, or at least not worth the trouble.
Title: Re: Getting my son's bike running better
Post by: knowles on August 12, 2012, 03:37:43 PM
its glued to it, i had to cut mine off in peices, so no not worth it.
Title: Re: Getting my son's bike running better
Post by: salamander on August 12, 2012, 03:47:50 PM
Good to know I'm not just a 260 lb weakling  :D.
Title: Re: Getting my son's bike running better
Post by: knowles on August 12, 2012, 03:55:06 PM
IF he wasn't ridden much it might be that hes not shifting hard enough, and the gear is only half in or out. unless you run it out of oil, or put the wrong kind in, or the thing comes apart, the clutches or really over built for this bike. its basically the same clutch as On the SV 650.
Title: Re: Getting my son's bike running better
Post by: salamander on August 12, 2012, 04:32:55 PM
Quote from: knowles on August 12, 2012, 03:55:06 PM
IF he wasn't ridden much it might be that hes not shifting hard enough, and the gear is only half in or out. unless you run it out of oil, or put the wrong kind in, or the thing comes apart, the clutches or really over built for this bike. its basically the same clutch as On the SV 650.
He's really just started riding, and has been doing more than short practice rides in the neighborhood only the last couple of weeks since he got his actual permit.  Even so, he only mentioned the slipping problem since we changed the oil at the start of last week, so I think he's got the hang of shifting gears.  The timing of the problem's also why I was asking about the oil earlier.  Turns out the clutch cable was tight and we adjusted it, so that may have been it instead of the oil.  I tried to talk him into taking the bike out today for a 10-20 minutes ride, but he already had other plans.  So, I'm still waiting to see if the problem's fixed.

Thanks.
Title: Re: Getting my son's bike running better
Post by: salamander on August 15, 2012, 08:24:07 AM
The weather finally cleared enough for the roads to dry out so I took the bike out myself for the first time since we started working on it (my son had been doing all the test rides before this).  I rode ~10 mi and did everything I could to get the clutch to slip -- accelerating with the rpm's up around 5-6k on level ground and on gentle hills -- but nothing like my son described, so I think the cable adjustment did the trick.  Thanks, AdidasGuy.

The bike responds much better to throttle, now.  When I open the throttle starting at ~4k rpm, there's no hesitation, no bogging, and the bike accelerates pretty smoothly.  But, even though I weigh in at around 260 lb, I still think a 500 should be able to accelerate better than this one's able to at the moment.  For lack of a better way of describing it, the acceleration is smooth, but not 'crisp'.  After looking through some other threads here and some other sites, I'm thinking this sounds like a rich mixture kind of thing.  We re-jetted to 40/140, but still have stock exhaust, so rich would make sense to me.  Please correct me if I'm wrong, or if there are other things I can check on.

One other thing that I did notice on the ride was that on a straight stretch I was maintaining ~55 mph and the bike started to buck a bit.  I headed to the gas station and filled it up thinking I had hit the spot where I needed to switch to reserve.  I went back out on the highway and it was still doing the same thing -- after maybe 10-20 seconds at speed, it started to buck a little and it would stop if I slowed and backed off the load on the engine.  I''m guessing fuel starvation, but again, if there any other possibilities, please let me know.

Thanks.
Title: Re: Getting my son's bike running better
Post by: RossLH on August 15, 2012, 11:46:37 AM
Check the orientation of the carb vent. If some turbulence is blowing up into the tube on the highway, it'll cause the engine to stumble.
Title: Re: Getting my son's bike running better
Post by: salamander on August 15, 2012, 12:46:26 PM
Quote from: RossLH on August 15, 2012, 11:46:37 AM
Check the orientation of the carb vent. If some turbulence is blowing up into the tube on the highway, it'll cause the engine to stumble.
We replaced the stock airbox with a lunchbox filter, but I still have the hose going over the top of the filter and just to the backside of it (so it's just below seat bottom level).  I also have a small cylindrical filter in the end of the vent hose to try to cut down on turbulence.  Does that sound like an okay positioning for the vent hose?

Thanks.
Title: Re: Getting my son's bike running better
Post by: RossLH on August 15, 2012, 01:39:55 PM
That should be fine. If you're worried about it being rich, pull the plugs and take a gander at them. If there is soot built up on them, you'll want to cut back the fueling.
Title: Re: Getting my son's bike running better
Post by: salamander on August 15, 2012, 02:11:41 PM
My son took the bike out for a while this afternoon.  As soon as it cools off a little more, I'll pull the plugs and let you know how they look.
Title: Re: Getting my son's bike running better
Post by: salamander on August 15, 2012, 03:19:53 PM
Quote from: RossLH on August 15, 2012, 01:39:55 PM
That should be fine. If you're worried about it being rich, pull the plugs and take a gander at them. If there is soot built up on them, you'll want to cut back the fueling.
The plugs currently in the bike have been in for ~120 mi, since the initial carb cleaning.  The first ~30 mi of that was put on before I adjusted the floats to stop an overnight leak of fuel into the left cylinder (and into the oil sump), but the remainder have been post-float adjustment, which I think is right but need to get a better-sized piece of clear tubing to confirm.  I just pulled them, and both look similar -- a little bit of light brown to one side of the of the electrode hook, and the rest of the insulator white, almost like new, but no sign of blackness or even dark brown.  Assuming 120 mi is enough, I'm surprised -- maybe I'm actually running a little lean, or on target.  The new jet sizes (40/140), washers (1 on the needle) and turns out on the pilot air screw (2.5 from closed) were blindly set from the re-jetting matrix on this site for a K&N lunchbox filter and stock exhaust.

Thanks.
Title: Re: Getting my son's bike running better
Post by: RossLH on August 15, 2012, 05:52:54 PM
Brown is a good color. A white electrode would indicate a lean condition.
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 15, 2012, 06:26:29 PM
He's talking about the insulator being white, which is ok.  As long as you are happy with with the performance with no hesitation or flat spots, then I would say that your jetting is good.
Title: Re: Getting my son's bike running better
Post by: salamander on August 16, 2012, 09:39:24 AM
Quote from: salamander on August 15, 2012, 12:46:26 PM
Quote from: RossLH on August 15, 2012, 11:46:37 AM
Check the orientation of the carb vent. If some turbulence is blowing up into the tube on the highway, it'll cause the engine to stumble.
We replaced the stock airbox with a lunchbox filter, but I still have the hose going over the top of the filter and just to the backside of it (so it's just below seat bottom level).  I also have a small cylindrical filter in the end of the vent hose to try to cut down on turbulence.  Does that sound like an okay positioning for the vent hose?

Thanks.
Either I misread your question, or just wasn't paying close enough attention, but what I described to you was the crankcase vent, not the carb vent  :embarassed:.  Starting from the T-connector at the carbs, the vent hose runs up and over the top of the air filter, then down, ending near the rear brake cylinder.  And, it does NOT have anything in the hose end -- the hose just stops and is open.
Title: Re: Getting my son's bike running better
Post by: BockinBboy on August 16, 2012, 10:49:55 AM
http://gstwins.com/gsboard/index.php?topic=60976.msg705284#msg705284

A link regarding the carb venting issues with the wind.

This is my bet on your 55+ mph stumbling problem.

- Bboy
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 16, 2012, 11:49:58 AM
Quote from: salamander on August 16, 2012, 09:39:24 AM
Quote from: salamander on August 15, 2012, 12:46:26 PM
Quote from: RossLH on August 15, 2012, 11:46:37 AM
Check the orientation of the carb vent. If some turbulence is blowing up into the tube on the highway, it'll cause the engine to stumble.
We replaced the stock airbox with a lunchbox filter, but I still have the hose going over the top of the filter and just to the backside of it (so it's just below seat bottom level).  I also have a small cylindrical filter in the end of the vent hose to try to cut down on turbulence.  Does that sound like an okay positioning for the vent hose?

Thanks.
Either I misread your question, or just wasn't paying close enough attention, but what I described to you was the crankcase vent, not the carb vent  :embarassed:.  Starting from the T-connector at the carbs, the vent hose runs up and over the top of the air filter, then down, ending near the rear brake cylinder.  And, it does NOT have anything in the hose end -- the hose just stops and is open.

I agree with jester.  Having the carb vent tube all the way back there will cause crosswind stumbling.  It should terminate somewhere that will be out of the wind.  In the stock set up, it terminates behind the airbox between the airbox and the battery, and is held there by a clip.  I think jester routed his over the battery and terminated it behind the battery box...I think.
Title: Re: Getting my son's bike running better
Post by: salamander on August 16, 2012, 12:33:56 PM
Quote from: BockinBboy on August 16, 2012, 10:49:55 AM
A link regarding the carb venting issues with the wind.

This is my bet on your 55+ mph stumbling problem.

Quote from: bombsquad83 on August 16, 2012, 11:49:58 AM
I agree with jester.  Having the carb vent tube all the way back there will cause crosswind stumbling.  It should terminate somewhere that will be out of the wind.  In the stock set up, it terminates behind the airbox between the airbox and the battery, and is held there by a clip.  I think jester routed his over the battery and terminated it behind the battery box...I think.
Thanks to both of you.  I'd read that thread about the wind and the vent hose, but it was a few weeks ago and I'd forgotten about it.  I can see how the hose, right behind my right leg with the pants flapping in the wind might have some turbulence around it.  When I hit the stumbling while riding, and it settled down after easing off the throttle, I assumed it was a starvation issue, but I also would have been going slower, so it could have been the turbulence.  I will re-route the hose, and I also plan on re-checking the float heights with some better clear tubing than I have now.

With the lunchbox air filter, I have a pretty big gap between the filter and the battery -- ending the vent hose between the two might not be a great idea.  That leaves me with really only two options: extending the hose to go behind the battery, or dropping straight down from the carbs to dangle the hose above the rear part of the engine.  Any suggestions about which might be more suitable?

Thanks.
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 16, 2012, 12:38:58 PM
I would go behind the battery for 2 reasons.  I think there will be less wind there for one, and two I wouldn't want the tube going too low or you might actually start siphoning the gas out of the carb bowl.  Probably not, but it's a thought.
Title: Re: Getting my son's bike running better
Post by: salamander on August 16, 2012, 01:16:17 PM
Thanks, I might have enough length to make it behind the battery, and if I don't, I can get a longer piece of hose.  Either way, I'll be sure to keep the end of the hose above the fuel level in the carb bowls.
Title: Re: Getting my son's bike running better
Post by: salamander on August 16, 2012, 03:07:52 PM
Sad as it is, my son goes back to school in about ~2 weeks, and I'm almost out of vacation days.  Trying to be realistic, I think we can get a couple more things done before we have to get back to the real world: 1) check the valve clearances, and 2) try to fine tune the carbs.

Figuring that #1 needs to happen before #2, I cracked open the camshaft cover and measured the clearances.  Both of the exhaust valves are the same: a 0.102 mm gauge slides in easily, but the next size up (0.127 mm) does not.  Both of the intake valves had clearances of less than 0.038 mm.  So, here's my plan -- if something sets off a red flag, let me know.

1. leave the exhaust valves as is -- I've seen the posts about using a larger-than-spec gap on the exhausts, and I'm going to give it a go.
2. order shims 0.05 mm thinner than the current ones to get back into the spec range.  Problem is, the numbers printed on the current intake shims are both 2.?5 -- on both, the second number has been worn away.  I have a micrometer around somewhere and hopefully I can dig it up; if not, I'll try to get one of the local machine shops to measure them for me.

Once I know the size of current shims, I'll order some new, thinner ones.  While I'm waiting, though: out of curiosity, when I eventually take the re-shimmed bike on a test drive, should I expect to see a difference, or am I just catching up on maintenance that probably should have been done sooner?

Thanks.
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 16, 2012, 04:14:43 PM
I wouldn't expect to see much difference with those measurements.  Might have to adjust the idle screw a small amount.  That is about it.
Title: Re: Getting my son's bike running better
Post by: salamander on August 18, 2012, 05:52:40 AM
Finally got around to getting the new shims for the intakes, and hope to have time today to get it all back together.  Just a couple of questions for those of you who have done this before -- it would be really nice to do this right the first time with no leaks.

First, the service manual says to put sealer in the groove in the cover before putting the gasket back in, so that's what I plan to do.  I have some of the Permatex Ultra Black.  Would this be a good choice for the valve cover, or would one of the other sealer types be better (higher temps, better resistance to gas etc...)?

Second, do I need to put anything on the lower surface of the gasket that contacts the cylinder head?

Thanks.
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 18, 2012, 07:10:06 AM
What you have there will probably work fine afaik.  You want to put a VERY SMALL amount in the groove of the cover just to hold the gasket to the cover for install.  If you put too much, you will be cleaning up the excess that squeezes out for a long time.  Dont ask me how I know.

The only place that you put any gasket sealer on the face of the gasket is a dab in each corner of the half moon shapes.  Just enough so it squeezes down to cover the whole surface on install.

If you don't have the special valve shim tool to hold the buckets down, I would suggest holding off this job until you get one.  It will save you a lot of headaches.  Some here will say you can do it with a couple screwdrivers, or by removing the cams, but it was way more trouble than it was worth trying to do it those ways for me.
Title: Re: Getting my son's bike running better
Post by: salamander on August 22, 2012, 07:11:07 AM
Quote from: bombsquad83 on August 16, 2012, 11:49:58 AM
I agree with jester.  Having the carb vent tube all the way back there will cause crosswind stumbling.  It should terminate somewhere that will be out of the wind.  In the stock set up, it terminates behind the airbox between the airbox and the battery, and is held there by a clip.  I think jester routed his over the battery and terminated it behind the battery box...I think.
I re-routed the vent to behind the battery.  That looks like the most out-of-the-wind spot I have available, but the stumbling is still occuring.

After a few more test rides using the same route, I noticed the stumbling happens at about the same place on the ride -- after starting off from a stop sign, I'm accelerating (fairly aggressively, for me at least) up to 55 mph while climbing some shallow hills, and it's shortly after that that the stumbling starts.  Going back to a fuel flow problem, I ran the route again with the petcock on PRIME and there was no stumbling; immediately ran it again with petcock in the ON position, and it stumbled at the same place in the ride.

I can't rule out a problem with the vacuum line to the petcock, but it seems more likely that there's something wierd with the petcock itself.  I'd like to get into the petcock to see if the ON passages are maybe partially blocked before I decide to replace it.  I saw the screws on the backside that I think would get me in, but is it possible to remove the rotating part of the selector from the front without destroying anything?  The backside would get me to the diaphragm (I think), but I'm more interested at this point in the passages in the rotating part.

Thanks.
Title: Re: Getting my son's bike running better
Post by: bombsquad83 on August 22, 2012, 07:18:13 AM
Replacing the petcock seems to be a very common repair when people buy older GS's.  I think that rubber diaphragm just gets stiffer over time and impedes fuel flow.  Ethanol in gas is probably contributing to the stiffening rubber these days.
Title: Re: Getting my son's bike running better
Post by: BockinBboy on August 22, 2012, 07:57:16 AM
Edit: Somehow posted message on wrong thread?..

- Bboy