My friends and I picked up an 89' GS as a project.  It would start but wouldnt idle without some throttle because of a carb issue.  Well we broke it down and cleaned up the carbs.  All cleaned up pretty well...The only issue is that both pilot jets were stuck and I didnt want to strip them trying to get them out.  So we pieced it back together and now it starts and idles (roughly) with the choke all the way open.  It didnt have much of a rhythm.  After it ran for a few minutes it picked up so we reduced the choke about half way and it went rough again and didnt recover much over time.  And when we apply even the slightest bit of throttle...the bike dies.   This is my first experience with a bike mechanically.  Does anyone have any ideas or suggestions of what we should look at or possibly adjust?   

I'm guessing you still have some crud stuck in the carbs.  What was your method of cleaning?

Jets clogged.. just went thru this. Do a search, tons and tons and tons of info.

We took everything apart in the carbs except the pilot jets which were stuck.  We cleaned the individual parts with dish soap and water and used some carb cleaner and water for the mass of it.  (we made sure not to use on or near the rubber parts.  It wasnt even around the inside parts)  Altho...we realized in hindsight that we didnt remove the choke parts but they were lubed up before being put on the bike and it opened and closed just fine.

well, if you keep getting the same problem. the main jets are clogged. just take em apart, if they break so what they're dirt cheap. Also, are you letting the bike warm up? these engines act like that if you don't warm them up. start it with full choke, let it climb to 4k, and inch the choke back so it stays there, let it stay at 4k for a minute or two and it should be warm enough. if after all that it still runs like crap then yea something's up with the carbs.

What about float height?

could be way out of balance

Ok   so I have decided to pull out the carbs again.  Does anyone have any suggestions on how to get the pilot jets out? 

Pilot jets are clogged.  One thing to do would be, to trim a single piece of wire off of a soft brass bristle bursh, and run it through the jet.  Maybe with a little gas to help dissolve and flush away the old, gummed up gas.

Pilot jet removal: I have really small-width-blade screwdrivers; you might have to grind one down to get in there.  If you can't get the jets out with that, and end up deforming them, you may need to use an E-Z out (kinda like a drill bit, but in reverse).

   Just opened up the carbs to take a look...and I am now extremely upset.  Not only was on of the float bowls full of grit lookin stuff...and not only was the float needle thing all gunked and caked in place...but the damn float was full of gas.  Fair to say this was my problem?   

yep sounds like it to me if you just cleaned them prior to this happening i would get a inline fuel filter in and also drain the tank

Welcome aboard.  Don't get upset, rebuilding carbs is a lot easier if you stay cool.  Parts are easy to get and not expensive so there's nothing to be riled about.  You know you need to clean the carbs well.  Gumout spray is fine and won't hurt anything.  You of course need new floats.  When you're done with that, check the float height.  If you don't have a gauge make sure they're even and lined-up with the top of the bowls.  Here's a link for the online Haynes manual:

http://www.scribd.com/doc/7178815/Suzuki-GS500-Full-Service-Manual

Before you put the carbs back on, make sure the tank isn't full of rust, otherwise your carbs may fill-up with crap again.  The fuel filter is inside the tank.  Clean it and make sure there are no holes in it.  It's gauze.  Check the manual.  None of this is very hard, just takes some time.  If the tank is rusty, Buddha can coat it for you at a very reasonable cost.  After that, make sure you have a GOOD battery for it.  An old, weak battery will make it run like crapola as it has battery ignition, not a magneto.

You picked a good bike.  It's very reliable and fun to ride.  It will serve you well if the previous owner kept oil in it.

Just curious, how many miles?

There is 7100k on it.  It hasnt even been plated since 98'

Do you have any idea what kind of fees will be involved with trying to plate it now?  Mine has sat for over 2 years and I'm curious what I'm going to have to pay to get it registered, titled, and plated.

Thanks,

Nick

As long as you have a clear title is doesn't matter if it was never plated.  Sounds like you found yourself a cheap little gem there.  Very little use for a 20-year-old bike.

.. and I thought I got a good deal...

Yeah...the low miles is why i jumped on it.  The previous owner also tracked down a front cowling and bottom engine cowling for it too.  It mostly just needs carb work, paint job, and other detailing.