I am working on an '04 GS500f that was very poorly neglected, and came to me in pieces.  I just rejetted the carbs, and am reinstalling them.  I am having trouble being sure the fuel and vacuum hoses are correctly routed.  Part of the problem is that the chlymer manual doesn't get to the gs500f, the haynes manual doesn't have a clear diagram of the routing for the gs500f with the PAIR etc., and I can't find a clear diagram as to what goes where online.

I know the T at the bottom of the carbs gets the fuel outlet from the frame-mounted petcock.  I know the top back T gets the auxiliary air filter.  There is a third T on the front, top of the carbs, between the diaphragm housings.  What goes onto that T, and where does it lead to?  (I assume this is a vent for the movement of the diaphragms, but it's taking unfiltered air, which makes me nervous).

On the side of the carbs there is a string of vaccuum lines.  I know the one that splits goes into the two white vacuum lift assist parts.  There is a black t in that assembly that I have connected to a line coming off the carbs, I think (not right in front of me).  There is one other white T.  What connects to that?  It was unconnected when I got the bike.

There is also a line that goes from the front of the airbox to the Valve cover.

It's just those two unpaired connectors I have a problem with.  Frankly, I can get the bike started as it is now, I just don't want to put the tank and seat back on, and then either destroy it or have to take it back apart.

Is there a clear diagram or pictures somewhere?  If not, we F owners should get some on here, because all the pics I can find are of an E, and they help me none at all.

Thanks again.  It's a work in progress, but it's proceeding.

Top one filtered

middle one is a breather (no filter, but I put some mesh around it to stop wasps building nests in it)

Bottom one is fuel

Thanks.  That's how I have it, it just makes me nervous that there is unflitered air involved.  where do you route that hose?  While I'm at it, where do you route the hose at the bottom of the airbox, and the vent on the gas tank?  There are tons of holes to put things, but there are also tons of moving parts...  Recipe for disaster, I fear.

Any pics regarding that web of vacuum hoses?  It's neat, with the carb off, it looks like a heart, with an aorta and veination.

I feel the same way working on my e... Just gonna have to finish up and hope it works 
good luck

The carb breather, airbox drain and fuel tank drain run down past the air box and exit on the lower right hand side of the bike (throttle side)


Here is a few pics that might (probably not) help







I'll see if I can dig up a few more.

Cool that kinda helps

What year is that?  Is that the infamous lunchbox air filter?  Is that a mini k&n auxiliary filter (cooooool...)?  How do you get the airbox hose down to the right side?  I can't get my hand inside the frame.

The top 2 pics are 2005

Yep its a lunch box and mini k&n auxiliary filter ( though I use a catch bottle instead as it doesn't drip oil all over my rear wheel http://gstwins.com/gsboard/index.php?topic=5180.msg428043#msg428043)


i used a looped piece of wire to grab my hoses to pull them out of the frame.


I'll have a look for those pics now. 

I'm not sure which thumb drive I stashed them on... hmmm. I'll have a look again later. 

I had a bunch of pictures i took while i was pulling my carbs off of my 06 GS500F, so i could get it back together properly. 

unfortunately i'm not at home and i dont have internet access at the hotel. 

i fly home on friday so i may be able to post them up then.

if you still need them, send me a PM so i can remember. 

actually.. i have a 2004.. i'm not sure why i said i have a 2006.  not sure if these help at all, but they helped me get mine back together. 








this is what it looked like before I pulled everything apart last winter.  luckily, this is also what it looked like when i put it all back together. 

Quote from: galahs on December 14, 2008, 09:56:39 PM

Bumping an old topic.



Got some Tygon Fuel line and I was replacing one of the carb lines when I forgot where one went.

In this picture, the line labeled "Pour Fuel in Here".  Where does that go?  I read the thread but I'm still confused. 


My GS thanks you all

pour fuel in here goes to the fuel output of the frame mounted petcock (where there are three more hoses  )

Quote from: skirecs on April 25, 2011, 11:04:22 PM
pour fuel in here goes to the fuel output of the frame mounted petcock (where there are three more hoses  )

hmmmm....  for some reason, the bike started without it but then i noticed it and shut it off after a few minutes.  Very odd. 

Is that line some kind of secondary?  Why was the bike able to run with out it connected?


Thanks in advance.  I'm bumping all these old threads because many are incomplete and I'm searching for all this info for my bike.  I guarantee the next person looking will be thankful all the info is here.  Without you guys, I'd still know nothing about this bike. 

friendly bump.


Can anyone tel me which valve from the gas petcock this connects to?  As far as I can see, there are only 3 outputs on the gas valve on the 01-02 version.  Am I just blind or should I pull everything off again?


Edit : guys btw, check out the views on this thread.  Seems like an awful lot of people had the same question I did over 3 years this was posted lol

Sorry guys, I made a mistake before.  The petcock lines were routed correctly, it was this line on top that was not connected.   Where does the one labeled "This One" go? 

Suggestions?  Thanks



EDIT:  Found the name.  breather hose for the float bowl chamber.  Keep the line in a place where it is well vented.  Hope this helps the next person searching. 

I believe that the top front fuel line is just a vent, you can rout it just straight down behind the air box.  It really doesn't matter, but theres no special connection.

Cue Zombie pics in... 3...2...1...

- Bboy

Hes out riding so give it a little time

I love an old thread back from the dead.

Now, we need one more oil thread and Ill be set for life