Been researching rejetting, as I am planning on rejetting my 2002 gs500 this weekend.  From what others have done, I have decided to go with a Lunchbox, pilot 20, mid-main 62.5, and main 142.5.  3 turns, and 2 washers.  My question is, on a 2002 bike, where do the washers go on the needle?  I'm assuming they are supposed to make the needle sit higher?

There is also a lot of conflicting reports on the part numbers, so if anyone has recently done, and has the parts, that would be appreciated as well.  Sudco.com still the best place to purchase those?  Oh, and where do I get the washers from?  I was reading the correct size for 2002 is M3 (3mm), sound right?

Any help/guidance would be greatly appreciated.

That all sounds like a good place to start.  Can't say for sure, but on mine, a '92, the washers go between the e-clip (little metal clip) and the plastic donut (not the one on top of the clip where the spring sits, but the one under the clip).  This has some great pics for the process for an older model, so just be aware of the differences.  http://www.angelfire.com/mt2/mikesgs500/rejetting/

And, as far as I know the M3 is the right size for the '02+ bikes.  Dunno where to get those I just got my #4 washers from Lowe's, the have a section in fasteners for stainless stuff...look there or check online.

Best of luck 

Yeah, the needle on the 02 is different, so I'm still not exactly sure how it goes.  Is the point to adding washers to make the needle sit a little higher?

On my 05 I just replaced the jets and didn't bother with the needle at all.

Runs sweet!

Does the 05 have three jets too:?  Where did you purchase the jets?  Thanks!

Quote from: toade on August 16, 2007, 09:45:57 PM
Is the point to adding washers to make the needle sit a little higher?

Exactly, my friend...the washers let the needle sit a bit higher and allow more fuel to flow in the midrange.  As for where to buy some jets check the wiki http://cgi.stanford.edu/~sanjayd/gs500/Upgrades/Rejetting as a place to start...a local dealer is also a great place to try,  that way you can see them before buying and have problems resolved faster.

I did a 65 mid and no washers on my 2001.  Runs like a champ.

And we shouldn't really be measuring needle shim as "number of washers."  Doesn't anyone know how many millimeters their washers are, so this can be standardized?