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GS500E Race build update

Started by Kurlon, April 18, 2008, 09:25:07 PM

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Kurlon

So, got a ton of work done on the bike this week.

Pingle installed, entire fuel and venting system simplified and made race legal
Keyless billet gas cap installed
Valves checked (.03mm is acceptable valve lash?!)
Jet kit
New front rotor and pads
New clutch lever
New headlight ears (to make room for clipons)
Clipons installed
Tail light, turn signals, side and center stands dropped
Springs, emulators and seals in the forks
Lots and lots of misc cleanup and race hardening

Left to do (installs) tomorrow:
Chain and sprockets
Install new Works shock
Safety wire
Settle on some sort of cover for the headlight bucket and it's wiring mess

Troubleshooting to do tomorrow:
Figure out why the nice new Pingle petcock barely flows, even with the gas cap off. It seems to have 'come into it' with a fidgeting, but I'd rather fully diagnose it than run into fuel starvation on the track.

Determine why my carbs are so out of whack that when 'synced' my idle is at 2k RPM and the idle screw is in my hand. Onto the bench they go tomorrow. I'm hoping it's something asinine like a plugged passage on one, easy stuff. That said, the bike had great throttle response with them 'synced' and idling high. : )

Relocate my left hand control cluster inboard of the clutch so the lever doesn't foul on it. (Generic clutch perch to make getting replacement levers easier, no one lists replacements for the GS, and AFAIK there isn't a common 'also fits' out there.)

Stumbling blocks encountered:
One fork required more effort than is appropriate to get the damping rod unbolted... no corrosion, threads are good on both the damping rod and the bolt... it's just a really tight fit for some reason?

Someone's had the front rotor off before, but I knew that as it had a toasted EBC on it. Unfortunately they used a 350ci V8 to torque the bolts, stripping them. I salvaged 4 and bought the last 1 the local Suzuki shop had in inventory, a fresh set of 5 is on the way.

Ordered tires a couple weeks ago, Bridgestone DOT race tires, 090 series.... called to find out where they were only to learn 140/70R17 BT090s have been on backorder for quite awhile... gee, thanks for telling me when I ordered... They tried to assure me a 150/70R17 would fit, without even knowing what bike it was going on which didn't make me any happier. For now, I'm going to run on the 130/70R17 Sport Demon that came on the bike as the rubber is still quite fresh to my surprise, and put a Michelin Pilot of some variety (whatever is in inventory at the shop) on front.
1991 GS500E - LRRS/CCS Novice #771

darb85

Check your throttle cable for the idle problem.  had the same issue loosened the cable a bit and it fixed it.  something to do with the clip ons under the tripple  :dunno_white:
2000 GS500E
K&N Drop in, Custom Turn signals, Kat Rear Shock, Pirreli Sport Demons, Woodcraft Rearsets. Kat Front Forks, Race tech .90, 14t

Kurlon

Actually, I suspect I forgot to plug a vacuum line on one carb after replumbing.  Of course I think of this at 1am as I'm trying to go to sleep... : )  I'll be able to confirm today.
1991 GS500E - LRRS/CCS Novice #771

coll0412

When you removed the vacuum petcock did you remember to plug the line that was attached to the right carb.

The fuel starvation from the Pingel petcock could be due to the shutoff lever thing being just slightly out of posistion. Try moving the lever and see if that improves the flow, the stop for the lever may be past the ideal spot.

As far as the 150/70R17 in 090's it will fit, it gets pinched a bit so you might not be able to get the very edge of the tire.
CRA #220

Kurlon

Yup, forgot to put a plug on the carb after yanking the vacuum line to the petcock.  Capping the port sorted it right out.
1991 GS500E - LRRS/CCS Novice #771

Kurlon

So, got the GS to the track Friday, and completed my race school on it sucessfully.  Noted two problems:  Still having poor flow rate problems with the Pingle setup if the tank gets down to about half full.  I was able to confirm it's not a tank venting problem.  Also had a flat spot at 6k RPM.  I had to smear RTV over the clutch pushrod and shift shaft seals, both were pushing oil at WOT.

Went out Sat, survived my rookie race and am now CCS Licensed.  Also got a race in and had a ball.  Flat spot still present, fuel flowed ok as I kept the tank topped off.

Sun I raised my needles 1 notch (DJ kit in the bike) and went out for practice in the rain.  That seamed to have cured the flat spot, but around lap 15 I crashed and wrecked my left hand so I didn't get a real good test of it in the wet.

I'm going to order new seals to fix thatr issue, as well as try to open up the motor's vent to lower internal pressure.  I'm going to take the tank off, and the petcock to try and sort it's issues.  I'll post pics later.
1991 GS500E - LRRS/CCS Novice #771

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