Hi all, new rider here.

I've been riding for about 4 months now.  Love it, when my bike is working.

Background:
I purchased a new 2005 GS500E, everything went well for the first 300km.  Then, I noticed the bike began to stall when coming to a stop, would pull the clutch in and the engine would just die.   At first I thought I had run it out of gas.  Put it in reserve and tried to start it.  Then I put more gas in the bike.  Choke out it would run just fine.  Would let it run for about 5 min and started putting in the choke.  Bike would drop below 1000 RMP and stall.  This would happen consistently.  Called the dealer and they helped me adjust the idle knob till it would idle ok.  As they would not come and pick it up from my house.  Nervously I rode it to the dealer.  

Turns out that the intake manifold was loose.  This would cause air to enter the carbs and stall the engine.

So they fix it.  I ride for another 300km.  Now the stalling has begun again.  I'm sure it has gas in it.  But no matter how warm the engine is, it stalls with the choke in all the way.  I suspect that the intake has loosened again.

Sorry for the long story.  Here are my questions.

Has anyone heard of something like this?

I feel like asking the dealer to come and pick up the bike  from my house at their cost.  As I don't feel that it's safe to ride.  Am I asking too much?

What if this happens a third time?  Do I have a lemon?  Should I talk to the dealer about buying the bike back?

Thanks for reading.

intake loose does make sense, but it it something you could fix yourself. It is not very complicated.

Otherwise, take it back to the dealer.

so you have 600 km on her and she won't run, and it's not the first time this has happened.  take it back, demand to see the manager, tell them that  your going to email suzuki about thier shitty service. and see if they are going to fix it then.

Funny, the intakes on my Triumph didn't loosen as much as they seem to on our GS'es. And, I figured out why I had that 'fuel starvation' hesitation at high speed, it was because I didn't check my intake boot clamps. Now, I really know why my right carb is all dirty (mild leak).

And, do take it to the dealer (they'll probably just locktite the screws).

Check your states lemon law - generally you have to lose the use of the vehicle for over 30 days and the dealer has to have taken three cracks at a fix without sucess before you can make them take it back

OK loctiting the manifold bolts is a bad idea, as is over torqueing it ... make sure its a mainfold that's taking in air ... then fix it the right way ... take it off and replacing it ... using a little bit of silicone or similar sealant is OK, excessive goopy crap is bad ... The design of the head/manifold has everyhting to do with how well they last ... My eliminator ones will never ever need to be replaced ... the thing is just like a sleeve ... the XS, the virago, the GS and the KZ are all disasters. To add insult to injury ... the eli ones are also easier to have carbs out and back in ... loosen it at both ends to fit it back and spray down with a shot of WD 40 and it slides on like butter ... Of course that stupid ass spring on the air box boot side was the worst freaking idea I've ever had the misfortune of replacing ...
Cool.
Srinath.