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Tard Farm / Re: Last Post Wins - V3
« Last post by peteGS on July 04, 2020, 07:27:42 PM »
Wow that looks like it was a big hit! I guess be thankful you were in the Spirit, not on the GS. I've been rear ended once on my 450 and that was not a pleasant experience. Thankfully it was all very low speed but still, ending up on the ground with no warning isn't something I would recommend.

Did you hand make the rear bumper originally?

Glad you were able to get it repaired properly too, nothing worse than "professionals" who don't do the job they advertise.

Good to see you got some Samantha faces in there too ;) Assuming that's her and not a self portrait??

Definitely looks like a lot of work went into it so far, hope you get to finish it soon and enjoy! :D
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General GS500 Discussion / Re: Missed Connection
« Last post by vasama on July 04, 2020, 06:59:59 PM »
Mr Buddha, thank you so much for your reply.

It became clear to me this morning, that there's a very significant difference in the signal generators of the two models. The old one, the one with 2 triggers, has only one protrusion in the rotor whereas the newer model has indentations all around. No wonder the thing didn't get going. My next step is going to be to replace that component altogether.
Too bad that I removed the old harness... Well, a bit more time re-installing it. Of course, crossing my fingers that this will do it.

It'll have to wait till tomorrow.
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General GS500 Discussion / Re: 2007 GS500 Running Poorly - Diagnostic Info below.
« Last post by bose_99 on July 04, 2020, 06:48:41 PM »
Seems as though it does go up to 6000 in most gears but i have to lean on to the throttle slowly.
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Tard Farm / Re: Last Post Wins - V3
« Last post by ShowBizWolf on July 04, 2020, 06:30:27 PM »
Made time for some pics. Very very abridged version but at least wanted to post up something.

To recap, the reason I took the car off the road was because it was rear-ended back in July of 2013. I was stopped, waiting to make a left turn, and it was hit into by a PT Cruiser which was pushed into me by a Sebring. Quite the Mopar party but not one I wanted to go to lol.


It was pretty bad IMO, especially this part:


I had to find someone who could weld and fix structural parts correctly. The first person I trusted kept my car for almost a year and did nothing with it... left it sit outside to become a home to critters and rust away. I had to have it towed out of his place and to another person. The second guy fixed the frame and installed new bumper shocks and a bumper and fixed up the damage in the trunk. Praise God.

After getting it back from him in October(ish) 2014, I had two choices. Either put some band-aids on the rest of it and keep it on the road... or strip it all down and refurbish everything. OCD won and I started the process of redoing everything.

Here are a few pictures from when I rebuilt the bumper flaring in the back.






This is a pic showing the back all repaired and painted. It's so low because there were no springs on the car at that moment.


It felt really good the day I put my plate back on.


In this pic you can see the new rear brake stuff, new springs and a little bit of the new gas tank. What you can't see is the reinforced spring mounts/seats and new spring bushings... but they are there!

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General GS500 Discussion / Re: Missed Connection
« Last post by The Buddha on July 04, 2020, 12:10:57 PM »
The TPS doesn't do anything.
You couldn't get it working with the advancer and the crank trigger off the 02 ?

The electrical should all be from the 2 trigger model so 02 wiring, ECU, crank trigger plate, advancer, coils, which looked like what you have. Just wont get a working tach - Just ignore that part.

Cool.
Buddha.
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General GS500 Discussion / Re: Missed Connection
« Last post by vasama on July 04, 2020, 04:59:52 AM »
Alright guys, should I start a thread on the Projects/Builds forum? (I'd rather keep it going here, if possible).

I'm finding out the hard way that it isn't a simple/straight forward 'unplug-plug' the harness replacement for this motor I got.

To summarize:
-Killed the engine on my '02 GS.
-Got an '07 engine on eBay. It is mounted.
-Found that the '07 uses a different igniter, and one sensor in the signal generator. Tried to cheat it by adding the second sensor to no avail.
-Got an '07 harness and igniter on eBay. Igniter arrives on Monday.
-Removed my old harness.
-Comparing both harnesses I saw that most of the old plugs are on the new one, but they are not a total match.
-Looking at the schematics of both years, I see that the newer has a plug for a Throttle Position Sensor, and a solenoid that goes to the igniter, the ignition switch and both the coils - This is not the starter solenoid relay; this one is a separate thing in the schematics.

I'm gonna dig online for the TPS, but my real hopes are that someone here will guide me in this endeavor. Methinks this engine should work, it might be a matter of an electrical component the '02 didn't have. Maybe it can be cheated and some of these circuits can be shorted out or ignored.
Before I removed the old harness, the lights turned on when I turned the key, and the engine turned. It just didn't send the spark on time - my best guess.

Fingers crossed that someone will give me advise or point me towards some.

Thank you all.

didn't take long to find the TPS thingy. Stupid thing goes on the side of the carbs... Oh, well..
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General GS500 Discussion / Re: Carb vacuum o-rings: US vs non-US?
« Last post by moxford on July 04, 2020, 01:12:35 AM »
Was more interested in the discrepancy, but swooped by HF and picked up a mad assortment of o-rings!

Thanks for the tip!

Cheers,
-mox
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General GS500 Discussion / 2007 GS500 Running Poorly - Diagnostic Info below.
« Last post by bose_99 on July 03, 2020, 06:29:35 PM »
Hey so I just got picked up an 07 gs5000 that wasnt running a couple weeks ago. The owner said he had been riding it last summer and it was running fine and after putting it away for the winter he came back to it and wasnt able to start it.

Background info:

At first there was no noise at all, but thanks to the help of this forum I was about find out it was a bust starter solenoid, so I replaced that and the battery because it couldn't hold voltage during crank and then the bike started up fine. Before I figured that out however, and prior to doing all the in-depth research that I now have done, I took apart my carbs  and completely cleaned them and soaked all pilot jets in the carb degreaser. While doing so I removed the float bowls from their housing, and removed the TPS via the screws as opposed to disconnecting it, broke off one of the vacuum inlets to the top white piece on one of the carbs. My friend who was helping me may have also fiddled with the small screw in between the carbs  (which im assuming is the mixture screw since I still havent been able to determine if i've identified the right screw as the mixture screw despite all the threads and pics ive looked at ). I have since reconfigured the TPS according to the the wiki and repaired the vaccum inlet.

I've also changed the spark plugs, and the front headlights and turn signal are not working but i have not tested to see if its a bulb issue or electrical as of yet. Neutral, oil, and speed lights are working however.

I've also seen some stuff about tightening the jets and then turning them back out 3 turns, I did not do this, just tightened until they were snug.
Also how do you tell if you need a new diaphragm (they were not perfectly circular, little waves on the top but no tears), I couldn't figure out how to get the needle out of it either and the need seemed stiff (I saw a video of a mechanic who said you should be able to move it up a little with your fingers, but this did not seem to be the case with mine).


Problem:
At present the bike starts up with full-halfish(choke lever is closest to rider, sorry if im wrong and this is actually no choke but this is my first bike and given the sporadic nature of its current performace  I cant tell which way is on and which is off) choke when cold but I need throttle pretty much everytime and it wont idle (I need to maintain some throttle to keep it running). 

While riding around with choke facing towards rider, I can get to 6000 or higher nearly everytime with the max RPM dropping a little with each gear (2nd ~5500 3rd ~5250 4th~5000 5th ~4500 ). Under no load (clutch in my drive way), I can hit about ~6000 in every gear. Sometimes I can get it to rev up to about 8k in neutral but this is pretty rare, but also its no often I try to rev it that high in neutral.

After warming the bike up with about 20 minutes of riding I turned the choke off (away from the rider) and i could the get the bike to idle with a good amount of regularity at about 1200 rpm. With the choke all the way off, the throttle response seems much better but i cant get the bike over 4000-4500 rpms in this setting and as a result cant get anywhere close to as much speed as I did with the choke facing me. If i turn the choke back towards me I get power back and rev back up to the same levels described above.



Sorry for the information overload but this is my first bike and riding has been great so far at low speeds but I'm dying to get it running how it should. Any help is hugely appreciated as always.
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General GS500 Discussion / Re: 2000 Suzuki GS500 - Horn won't shut off
« Last post by benoitrenaud on July 03, 2020, 05:34:06 PM »
Hi,

I took it apart, had a hard time removing the horn switch  :technical: . Everything looked find. I think there must be some wires touching somewhere.  And the headlight low beam is not burnt, it's just the horn sucking more power from the battery. I notice when I disconnect one of the wire from the horn to stop it the headlight low beam goes out, I guess they are connected somewhere, I think if I find this it may resolve my horn problem.

Thank you,

Ben
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Hi All,

I've have a project GS500 which I've been working on for ages, and it appears I am so close to actually riding it!!! Looking for some pointers on an issue I've come across if possible...
I had it running with the previous (original) engine but it threw the crank, so I've recently replaced the engine. when doing this, I made the a couple of changes and these are my thoughts towards them...

1, replaced the stator as the original was damaged (engine didn't come with one). The 3 yellow wires had different connectors so I've temporarily connected them directly. My question here is whether they need to be connected in a certain order? Testing them didn't show any current variation so I assume not, but could be wrong...

2, The new engine doesn't have the outlets for the PAIR hoses so I've removed this and plugged the vacuum hose. I assume I don't need to do anything further here... unless maybe change the fuel ratio?

Aside from this, here are the videos of the bike starting:

https://youtu.be/5CnNUZ9z0aQ

https://youtu.be/2Dpwm87wi2E

https://youtu.be/9H-5WNXEXv4

3, If my above point are on the wrong lines and you know what I've missed, can you please let me know so I can get to riding :)

Thanks for taking the time to help if you can
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