I am hopeing someone has dealt with this before.

99' GS500E- I took my baby out today for the first time since I rebuilt the carbs.  I mean really took her out. 70-90 mph for 20-30 miles.

When I get her home she's pissing fuel out of the airbox vent line. I know I must have done something wrong but have know clue what it could be. The carbs have two small ports at the bottom of the intake and fuel is pouring into the airbox from these two holes.

Only when she is brought up to operating temps and run a bit hard. and after a few minutes it will stop pouring out the air box vent line.

Any help is greatly appreciated.
I feel like a kid with a toy he cant play with. 

Two primary possibilities -

1.  If you hook up the hoses wrong you can end up dropping fuel into what are supposed to be vents - check the hose connections from the petcock to the carbs.

2. Stuck float/float too high after rebuild

Quote from: mjm on February 02, 2006, 09:33:51 AM
Two primary possibilities -

1.  If you hook up the hoses wrong you can end up dropping fuel into what are supposed to be vents - check the hose connections from the petcock to the carbs.

2. Stuck float/float too high after rebuild

I triple checked the hoses and vent lines twice already. (I had an earlier incident that hydrolocked my engine, last year - so I a bit paranoid about them) I checked them over and over.

As for the float I made sure they were within factory specs when I rebuilt the carbs.

It might be sticking though. any clue on how to check? or remedy?

I am going to drop the float bowl tonight, but don't know what to look for, since everything was fine when I put it back together this weekend.

Any ideas?

oh yeah, one point I forgot to mention. Just before I went on this small trip, I filled her up to the gills with gas.

Has anyone come across having the carbs dump fuel into the airbox after filling up the tank?
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another Idea is maybe the petcock is malfunctioning? would a bad petcock flood the carbs, if the floats were working properly?

I've had a little gas coming out of my air vent hose before...

If the GS has been tipped over or WAYTHEHELL overfilled, the fuel can go where it shouldn't...  At least, that's what the head mechanic at a Suzuki shop told me.

symptoms are gone.

must have been a stuck float or a bit of rust from the tank.

oh well!! 

i find if i really thrash the gs for quite a while i get the same thing, i was worried at first, but i checked every thing out and all was good so i dont worry about it now,
it still happens now and then but i dont ride it as hard as i used to.