I bought a GS500e with a GS500f parts bike.  The petcock on the e (from '02) doesn't work so the old owner swapped the '04 on.  Can someone tell me what lines need to go where?  Pics would be great.

Thanks,
Steven

The tank shutoffs are the same for all years so it should hook up like a 04-09 with the 04 petcock.

Thanks for the picture.  That is helpful. 

Any idea what dimensions for lines to buy if I wanted to replace the old hoses? (or should I go oem?)

Fuel hoses are 7mm, AFAIK. It's a hard size to find; most people will try to sell you imperial hose sizes. 1/4" inch will fit, but will be very tight. 5/16 will fit, but be very loose. You can use 5/16 with some good hose clamps.

BTW... If the bottom end of the GS500F engine is good, I'd be interested in buying it from you. Probably worth about as much as you paid for the bike, and I can offer some engine bits in exchange if there's anything you want to keep as spares.

Quote from: burning1 on November 27, 2011, 11:46:34 PM
Fuel hoses are 7mm, AFAIK. It's a hard size to find; most people will try to sell you imperial hose sizes. 1/4" inch will fit, but will be very tight. 5/16 will fit, but be very loose. You can use 5/16 with some good hose clamps.

BTW... If the bottom end of the GS500F engine is good, I'd be interested in buying it from you. Probably worth about as much as you paid for the bike, and I can offer some engine bits in exchange if there's anything you want to keep as spares.

I prefer 1/4". I got it on fairly easy by lubing up the tube with some gasoline (it's all I had available) and then using a pair of pliers to coax it into going on. Upside is you can use the stock clamps.

Quote from: burning1 on November 27, 2011, 11:46:34 PM
Fuel hoses are 7mm, AFAIK. It's a hard size to find; most people will try to sell you imperial hose sizes. 1/4" inch will fit, but will be very tight. 5/16 will fit, but be very loose. You can use 5/16 with some good hose clamps.

BTW... If the bottom end of the GS500F engine is good, I'd be interested in buying it from you. Probably worth about as much as you paid for the bike, and I can offer some engine bits in exchange if there's anything you want to keep as spares.

Sounds good.  Let me know what you need.  I don't plan on keeping the parts bike long after getting the '02 running.

No luck getting the bike to fire.

The bike runs if I shoot some carb cleaner in there but I was unable to get the bike to fire via gas in the tank.  The two lines from the tank to the petcock are fine and gas is getting through.  The main line off the petcock is in the right place.  I'm not sure about the vacuum line though- and ideas where to connect it on a 2002 e model?  There didn't appear to be anywhere on the left carb (Same side as the petcock). 

Thanks.


Edit: I think I might have found the vacuum port but it is capped off.  The carb is an '02 and the petcock is an '04 model.  Should I try and connect it?

If everything else is OK it should run now with the petcock set at the PRI position, prime bypasses the vacuum shutoff.  I've only done about 20 valve checks putting 91k miles on my 02 GS but don't remember for sure where that vacuum hose goes.  I think it hooks up inside the left carb, a similar port on the right carb is plugged off.

Well I thought the bike might be flooded so I decided to drain the carbs.  Absolutely nothing came out.  Next step- remove the carbs.  Holy crap there was a mess.  Everything had a brown glaze inside.  I cleaned everything the best I could and let the jets soak.  I will resume work tomorrow evening.