Quote from: Garrett on June 02, 2011, 01:10:38 PM
I am wondering if I crossed something when I put it back together.

is this correct? Pic is from ebay.



Where does the vacuum tube for the petcock go? On the side of the one of the carbs, right?

That is correct.The vacuum port is on the left carb near the copper tube on the back and side.I will get a pic of mine in a bit and post it.

Awesome. I will pull my tank off tinight and check/clean the tank petcock after pulling the drain screws and feed line to see if its getting fuel.
If you could get a pic and maybe label things Id be forever grateful thanks a bunch.

My vacuum ports are capped off with automotive type vacuum port covers.

Wait there are two? I only remember one line going to the frame petcock. should there be two?

Quote from: Garrett on June 02, 2011, 02:56:05 PM
Wait there are two? I only remember one line going to the frame petcock. should there be two?

only on the left side. follow #53 in the diagram http://www.bikebandit.com/1994-suzuki-gs500er/o/m6054#sch245352

i believe the right side is blocked internally..or it should be anyway

Pulled the tank. Cleaned the pet chicken. Check for fuel at the feed line, my hand got covered in fuel so that's a yes.

Started it up. Let it idle for a minute. Gave it some gas. Stumbled then died. Now just cranks and cranks and cranks. I am totally lost.

Quote from: Garrett on June 02, 2011, 02:56:05 PM
Wait there are two? I only remember one line going to the frame petcock. should there be two?

My bike has two operational vacuum ports.Why,I dunno.None of my other bikes have two.Just the one shown in the carb diagram above.

Quote from: Garrett on June 02, 2011, 06:02:35 PM
Pulled the tank. Cleaned the pet chicken. Check for fuel at the feed line, my hand got covered in fuel so that's a yes.

Started it up. Let it idle for a minute. Gave it some gas. Stumbled then died. Now just cranks and cranks and cranks. I am totally lost.

Make sure the petcock is set on PRI(prime).Also check the tank petcock to make sure it is turned on.

Affirmative to both of those. 

Are you now getting good flow out of the carb drains with petcock on 'prime'?

Have you checked float height?

WEnt out to try to start it. Smelled fuel. Noticed the carbs were not attached. WTF. reach my hand on the air filter to push them. air filter is SOAKED in fuel.

Put the carbs back in and tightened the clamps. Started up. Idled at like 3k with out the choke. Dialed the idle back to ~900rpm. Shot back up to 3k as soon as I revved it and stayed there. Dialed the idle back again to ~900. That's where it's staying with the petcock on ON.

Stalled after a few minutes. Went out and started it up. Died instantly. Put the petcock to RES and it started up. Put petcock back to ON and revved it. Jumped the idle up to 4,000RPM. Dialed the idle screw back to ~900.

Stalled again. Started it up on RES. Idle slowly climbed to 4,000rpm again. Dialed back to ~1000rpm and holding.

Idle climbed back up to 3,000RPM. DIaled idle screw back to ~1000 and holding

Sounds like you may have bad float needle(s) or a sticking float hinge.Fuel soaked air filter is a sure sign of sticking floats.I would seriously suspect that there is fuel in the oil sump.If the oil level is high or smells like gas.It needs to be changed.Fuel in the oil will wash the cylinders and bearings of oil.It will also thin the oil out.

Float needles being the small things that mount to number 28

It's been holding idle for ~10 minutes. I just revved it and it revs up fine but it "sticks" when it's coming back down to idle.

The floats are number 28 on that diagram, and yes,the needles are the little things that connect to them and have a pointed end.I don't have a set free or I would post a pic of them.You could also have bad O rings on the needles seat allowing fuel to flow around the needle and seat assembly.

So would you recommend replacing the floats and needles?

http://www.bikebandit.com/1989-suzuki-gs500ek/o/m6049#sch246540

which one is the float needle?

Quote from: Garrett on June 03, 2011, 09:51:07 AM
So would you recommend replacing the floats and needles?

If they are sticking I would replace the needles,seats,and O rings.Here is where most of us get our carb rebuild kits.It's about half way down the page.P/N #48-1947 http://www.partsnmore.com/parts/suzuki/gs500e/?filters[fitting]=custom

I replaced the o-rings when I jetted it