Could someone please post a pic of the correct routing for the Carb vacuum hoses. I think I hooked them up wrong and can't seem to find a pic anywhere, including the Haynes. Rpms don't go over 1500 with choke wide open and slides in both carbs flutter when opening throttle, causing bike to want to stall, accel poorly and be very difficult to ride. Please help. Ran fine last season.

There are no real diagrams for the emissions equipped bikes.I believe that each year is different after 02.Hopefully someone here has access to Suzuki shop manuals and can post a pic,if there is one,of the emission hose diagrams.

Hey I've been having exactly the same problem with my 2008 California GS. What year is yours, and is it CA? I spent hours looking for a vacuum diagram in both the Haynes manual and the Suzuki service manual, but there's nothing. Then, as I was staring at the bike's guts trying to just figure it out, I noticed a little sticker on the top of the rear fender (under the seat), labeled something like "vacuum routing diagram." It was much more useful than anything else I could find, but the diagram is tiny so it's still a bit confusing. I was able to get the bike running, but I think I'm still having some kind of vacuum issue, because since putting it back together my tachometer needle bounces up and down every once in awhile, and the choke acts a bit weird. Other than that it's running great though, no stalling or anything.

Do your carbs have a vacuum outlet in the usual place, on the inside of the left carb? If not you probably need to do the same thing I did (except whatever I did to cause the tacho problem). Look on your rear fender for the diagram, if it's not there I'll send you a pic of mine. Good luck and hang in there, I know how frustrating this can be. 

I'm on an 06. Not sure about the California part, but it does have the emission control valve that runs to the air box. Can't seem to find this sticker you mention. Might be something they added after my model year. A picture would be great if you could get one.

Does your state have any emission inspection requirements?  If not, I'd just remove all the non-critical emission control components and greatly simplify your vacuum system.  Basically make the vacuum system on your newer GS like the older GS's.

Forgive me, it's been a couple years since I've last had my tank off, so I'm a bit rusty on specifics of the GS and can't give you more info right now.  Off the top of my head, the only things you really need connected are the petcock and the PCV vent (which can also be vented to atmosphere with a small air filter).  I think there is a solenoid valve and a charcoal canister that you can toss.  I don't know if there are any other complications that would arise from this and I haven't tried it myself (and I can't remember why I haven't).  

I'll be doing some work on my bike in the next week or so and am planning on pulling all of this off while I'm in there to save weight since my state doesn't inspect.  If I find it feasible and I have time (and no one else has written own) I will do a quick write up on it.

Quote from: TheDrunknmonky on May 30, 2011, 05:40:01 PM
I'm on an 06. Not sure about the California part, but it does have the emission control valve that runs to the air box. Can't seem to find this sticker you mention. Might be something they added after my model year. A picture would be great if you could get one.

I'm in the middle of moving to a new apartment so things are hectic, but I should be able to get a pic of the diagram posted within the next couple days. Just to make sure the diagram would be useful to you--Is there a vacuum outlet on the inside part of your left carb, where all the how-to's say it's supposed to be? If so you can just connect the vacuum hose from the petcock directly to that and be done. If, on the other hand, you see a bunch of 3-way connectors, and there's no vacuum port on the inside left carb, yours is probably like mine. I'll get the diagram up soon though either way, it might be useful for others too.

3 ways and no connector on left Carb. Michigan does not emission inspect anything.

Cool, my diagram should work for you then. I can't take a picture of it until I pick up my bike from my old apartment (damn movers wouldn't put it in the truck, so I have to bus back and get it), but I'll get it posted asap. It definitely worked for my--I think the bouncing tachometer needle is due to a dying battery, not a vacuum issue.

I'll hold tight.

Here's the pic of the sticker on my rear fender:



Here's a direct link to the pic on flickr in case it doesn't post here:

http://www.flickr.com/photos/63425569@N04/5788595416/

I hope this diagram applies to your 2006. Mine is a 2008, but from your description it sounds like you have the same vacuum routing.

Quote from: paalak on June 01, 2011, 06:13:21 PM
Here's the pic of the sticker on my rear fender:



Here's a direct link to the pic on flickr in case it doesn't post here:

http://www.flickr.com/photos/63425569@N04/5788595416/

I hope this diagram applies to your 2006. Mine is a 2008, but from your description it sounds like you have the same vacuum routing.

After seeing that diagram,it a wonder the damn things run at all.There's more potential leaks there than the city sewer.

Omg.. that is exactly my setup. I don't know how i managed it, but I really hooked my lines up wrong. Thank you so much. Problem fixed. My baby sounds happy again. And I can finally ride her.

So I switched from f*ckr to photobucket, and now the image is showing up. Glad it worked for you Drunken, I think you'd have to be a pro mechanic to figure that mess out without a diagram.

I hear ya Ben, it seems pointless to add all that complexity for that emissions crap that probably doesn't make much of a difference. One of the reasons why I chose the GS500 for my first bike was its rep for being easy to work on. If I'd known about this change in the vacuum routing I'd have looked for a pre-2004 GS. Other than that, though, I'm happy with the bike, and the silver lining is that I ended up learning a lot about my bike trying to figure this out. 

Quote from: paalak on June 02, 2011, 11:12:02 AM
So I switched from f*ckr to photobucket, and now the image is showing up. Glad it worked for you Drunken, I think you'd have to be a pro mechanic to figure that mess out without a diagram.

I hear ya Ben, it seems pointless to add all that complexity for that emissions crap that probably doesn't make much of a difference. One of the reasons why I chose the GS500 for my first bike was its rep for being easy to work on. If I'd known about this change in the vacuum routing I'd have looked for a pre-2004 GS. Other than that, though, I'm happy with the bike, and the silver lining is that I ended up learning a lot about my bike trying to figure this out. 

Do you mind if I swipe that pic for future referencing?

Don't mind at all--if you have trouble downloading it or anything, PM me your e-mail and I'll send you the file.

Quote from: paalak on June 02, 2011, 04:35:20 PM
Don't mind at all--if you have trouble downloading it or anything, PM me your e-mail and I'll send you the file.

I got it.Thanks.

I copied the pic to my phone's SD card and threw it in the same folder as my PDF copy of the Haynes manual that I have. Thanks again.