So I changed the jets on my 91 GS500E to 127.5 mains and 40 pilots, put two washers in, and evertying seemed to go smoothly until I tried to start the bike and was greeted with nothing.  If I opened the float drain, gas would come out so fuel was getting to the carbs so I tore the bike apart and found the carbs FILLED with gas, gas coming out of the drain of the airbox, etc.  I think the problem was that I had the idle air screw out too far, which I corrected.  The bike started for a second then died when I hit the gas and does not start anymore.  Could the problem be that the same gas that got in the airbox got into the engine??

Thanks
~Sonny

Gas overflowing = float needle not sealing, or the oring around the float seat is leaking (that one happened to me... just put in a new oring and I was fine!)

Do a float height check to make sure your floats are at proper height and that your needles are seating properly... start there and see what develops

Thanks ill check that out.  One more thing though, there is a hose coming from the right side of the battery (not the battery itself but its on the right side of the battery box and I dont know what it's connected to) and ill be damned if i remember where it goes.  Is this the breather hose for the gas tank?

Also on that note, in addition to the petcock, there are two more places to connect hoses coming off the bottom of the fuel tank.  One of them is curved 90 degrees and the other is straight, theyre pretty far apart and the one that is curved had gas coming out of it when i was flipping the gas tank over and such.  What are these 2 guys for??

thanks again!

There should be a hose attached to your tank drain... it passes over the airbox, so that may be the one you're talking about.

Quotein addition to the petcock, there are two more places to connect hoses coming off the bottom of the fuel tank

Both fuel hoses coming out of the tank only go to the petcock. There are 3 hoses coming out of the fuel tank, one drain and then a fuel line and a reserve line. I think you need to re-ask your question.

If you disconected them from the frame mounted petcock, and you didn't close the tank mounted petcock, then yes you will have fuel coming out of them, if there's nothing stopping the fuel from flowing, gravity will just draw fuel from the tank. If it only comes out of the one with the 90 degree curve before entering the petcock, that means that you only have fuel below your reserve mark.

QuoteWhat are these 2 guys for??

those 2 fuel lines... well they're fuel lines... 

This is the hose that I was talking about that came off of the right side of the battery but i have no idea where the end in my hand goes to:



This is the bottom of my fuel tank showing two nipples which I know are the main fuel line and the reserve on the petcock and two more one to the immediate right of the petcock and one more far to the right of the tank.  I dont know what the two nipples that arent on the petcock are for.



Might be hard to see in this picture though.  Also fuel comes out of the one on the far right (90 degree nipple) even when the petcock is in the closed positioin (no fuel comes out of the reserve or main fuel nipples on the petcock)

i guess my previous question was pretty poorly worded haha

Maybe this will help

http://www.gstwin.com/fuel_hose_routing.htm

Nipple to the right of the petcock is the fuel overflow/air drain hose. One end plugs into that the other is routed inside the bike and doesn't connect to anything

I'm not sure about the Battery one... I have a drain that leaves from my battery overflow and goes down  just in front of my tire, and it looks like you don't have a hose on your battery overflow... or maybe I just can't see it.

Check your airbox, does it have a drain hose coming from the bottom of it? If not that may be it, but mine is much longer and looks like it would be thinner than the one in the picture, and mine also has a drip spout at the bottome end that comes out near the right footpeg.

For the tank, the first nipple to the right of the tank petcock is the overflow, the one on the far right, I'm not sure about... I don't have one on my tank... but it looks like there was some work done on that tank... and it doesn't look like it was done too well... looks like crap.

Lastly, about that hose, did you disconnect it? If you didn't then I wouldn't worry about it unless someone figures out where it goes. But if you did disconnect it... Here's a good learing experience... always label things before disconnecting them! 

I'm 99% sure that i didnt disconnect it because it has a clamp on it and i would have remembered taking off that clamp, i think it was just there.  BUT i did open up the float bowls again, double check everying, checked to see that the jets were clean and clear, checked the float height (which were spot on) and changed the float seal (the float seal is the orange thing on the top of each carb in the picture here right?? cause those did seem to be pretty loose and the replacement fits much better)

Anyway she still wont start!!     It cranks over and sounds like its close but it never catches...really dont know what to do next.

Thanks alot guys, I appreciate your guys quick responses and patience

Shot in the dark, but did you use bleeder type pilots or non bleeder?

Im going to say that your jetted way to rich. Im assuming you have an airfilter and exhaust on your bike. So do I and when i tried 40 pilots it ran like shaZam!. And Im not sure that it needs two washers under the needle jet, try taking one of those out. Your main jet should be good, though. Also check the mixture screw, you might be able to get away with turning it way in now with the 40 pilots. Take the plugs out and look at them, are they all fouled? covered in gas?

I used non bleeder pilot jets but tried Chris_B's advice and switched back to the stock jets and took one of the washers out from under the neddle jet.  I also pushed the mixture screw back in so its at 2 turns out now.  It still doesnt start...sounds like its farther from catching now than it did before.  At this point im starting to get a little worried about draining my battery because of trying to start it so long withot it ever running 

update:
Bought a battery charger and starting fluid thing, tried the starting fluid and it would catch but misfire a little and die pretty quickly (a few seconds) and only really clung to life by my opening the throttle.  I guess ill let the battery charge some while I change the pilots back to the 40s and reinstall the washers or is this a bad idea??  I cant help but wonder if the hose that I was talking about before that was to the right of the battery box has something to do with this though...

Since you went back to the stock pilots, youll need to back it out to the original setting(the mixture screw) or it will run lean. sorry i didnt make this clearer. I was trying to say if you leave the 40 pilots in try and turn the mixture screw in a bit to compensate for the bigger jets.   The engine wont even try to catch with the mixture screw that lean and the stock pilots.

Just for a little clarification...

On the mixture screws, does in = richer and out = leaner....Or is it vice versa?

Quote from: skoebl on May 07, 2006, 01:01:31 PM
Just for a little clarification...

On the mixture screws, does in = richer and out = leaner....Or is it vice versa?

Out = richer, in = leaner.

Re hoses: I think you have the California model with the charcoal filter canister under the battery box. This has a few hoses more than a standard GS, and the contraption is often removed.

yeah thats definately what it looks like, i traced the hose and it connects to a box under the battery box...so then what does that hose that im holding in the pictures connect to???

SHE LIVES!!!

but there are a few tuning issues...it seems that if i turn the choke off it revs higher (idles ~6k) but if i turn the choke on the RPM's drop (if i fully choke it, it will die after a little bit).  I don't know but this means its running lean(??) so should i adjust the mixture screws or what?

7b

I think what happened is that the first time I assembled the carbs back up from changing the jets, the oring by the float needle was leaking causing fuel to fill up in the carbs which made it run way too rich and leak fuel everywhere.  Because it took me a while to figure that out and such, I had tried to start the bike many many times.  I feel this depleted the battery to the point that it would turn over but not have enough juice to spark it.  I charged the battery and put some of that starter fluid that you spray into the carbs before I reassembled eveything.  With the battery charged it still took some effort and a good amount of throttle to get it to catch, but without a charged battery it would not have been possible to get it to spark.