Hi Folks,
I just scored a semi-running 2001 GS500E from Craigslist. I'd post a pic, but it's already apart in the garage. It was covered in dirt, but I cleaned it up and it actually looks pretty good. It has fueling issues, mainly from sitting and from the pod filters and homemade exhaust the previous owner devised. My plan is to clean the carbs and set it all back to stock, then see where it's at. I'm pretty excited about this project.
I might as well ask a few questions while I'm here, if you don't mind.
1. A quick search tells me that a GS500F exhaust will fit on the GS500E. Are there any subtleties I need to know about for my 2001? Anyone have one in the garage they'd be willing to part with?
2. Is there a non-sketchy place to download a repair manual? If not, any thoughts on Clymer versus Haynes?
3. Does anyone have any images of the fuel line routing? The PO removed the airbox and installed pod filters. The airbox was gone so he simply hooked up a bunch of fuel hoses in a pretty random manner. If anyone has a pic or diagram of the actual routing of the fuel lines I'd really appreciate getting a look at it.
Thanks in advance,
Jim Moore
Jax, FL
Quick google found this:
https://www.manualslib.com/manual/793090/Suzuki-Gs500e.html
Fuel routing should be in there.
Welcome to the board, best of luck as you rebuild. Hope you get it running asap!
2001+ has a larger fuel tank, and with it a different set of plastics and a different seat. These items must go together.
They switched from a mechanical to an electronic tachometer.
They changed the signal generator.
And they switched to a 3 jet carb with a slightly different airbox.
Everything else is essentially identical. Exhaust, engine, frame, wheels, chain, brakes, forks, electrics, all the same...
You can find a PDF of the factory manual in multiple places by just a Google search, but the Haynes is good at cutting away the BS and giving you tips for maintenance.
Here's your hose routing.
(http://www.gstwin.com/images/how_to/fuel%20hose/www_gs500_de_HoseRouting.jpg)
Quote from: Suzi Q on February 21, 2017, 09:28:53 AM
Quick google found this:
https://www.manualslib.com/manual/793090/Suzuki-Gs500e.html
Fuel routing should be in there.
Thanks. That worked like a champ. I had seen it earlier, but I was wondering if it was a legit site. If my computer gets taken over by the Russian Mafia I'll know it wasn't.
Quote from: Watcher on February 21, 2017, 12:03:18 PM
2001+ has a larger fuel tank, and with it a different set of plastics and a different seat. These items must go together.
They switched from a mechanical to an electronic tachometer.
They changed the signal generator.
And they switched to a 3 jet carb with a slightly different airbox.
Everything else is essentially identical. Exhaust, engine, frame, wheels, chain, brakes, forks, electrics, all the same...
You can find a PDF of the factory manual in multiple places by just a Google search, but the Haynes is good at cutting away the BS and giving you tips for maintenance.
Here's your hose routing.
(http://www.gstwin.com/images/how_to/fuel%20hose/www_gs500_de_HoseRouting.jpg)
Thanks. That was just what I was looking for. On my bike the hose from the upper T was connected to the fuel tank. Based on the image I don't think that's correct. Do you concur?
Connected where on the fuel tank?
Actually, doesn't matter.
Top T is a vent/breather, bottom T is the fuel in. Nothing should connect straight from the tank to the carb, both fuel lines should go to the frame petcock and one should go from there to the carbs.
The breather from the tank should exit more or less behind the airbox.
Quote from: Watcher on February 21, 2017, 03:10:43 PM
Connected where on the fuel tank?
Actually, doesn't matter.
Top T is a vent/breather, bottom T is the fuel in. Nothing should connect straight from the tank to the carb, both fuel lines should go to the frame petcock and one should go from there to the carbs.
The breather from the tank should exit more or less behind the airbox.
Thanks. That's what I thought. The line was running from the top T to a drain tube under the tank. I think it was a case of the PO having a hose and looking for a place to plug it in.
That pic above is for 89-00 bikes, the 2 fuel lines from the tank shutoff to the frame petcock actually cross on 01-02 models only. There are 3 different frame petcocks for all the 89-09 bikes.
(http://img.photobucket.com/albums/v443/jcp8832/GS500fuelcocks_zpsfcb7992c.jpg)
Top view of hoses:
(http://img.photobucket.com/albums/v443/jcp8832/top%20view_zpsdgdjolxi.jpg)
Thanks. Looks like the hose to the carb goes under the airbox. Right?
Quote from: Watcher on February 21, 2017, 03:10:43 PM
Connected where on the fuel tank?
Probably to the little nipple that goes to a tube that crosses from the bottom of the tank to the top, venting under the fuel cap. There's a clear vent from that spot under the fuel filler cap that goes straight through to the bottom. On my bike nothing is connected to it. On my '92 tank there was no such vent. I have no hose that looks like it is supposed to go there. I assumed it was a CA smog thing and somehow the CA bikes had extra plumbing for it, but who knows. Maybe all '03+ have it.
Quote from: mr72 on February 22, 2017, 01:48:56 PM
Quote from: Watcher on February 21, 2017, 03:10:43 PM
Connected where on the fuel tank?
Probably to the little nipple that goes to a tube that crosses from the bottom of the tank to the top, venting under the fuel cap.
That's what I figured but my curiosity was short lived.