Over the winter, apparently my gas got bad because I was driving it, and as soon as I let go of the throttle, it slowed down like the brake was on. Eventually it stalled out and I could not get it to start. It was dripping gas out of the air box drain hose. The gas was brown.

We took apart the carb and cleaned it. We cleaned the air filter and air box out. I replaced the 2 spark plugs in it. Now, it starts up but after about 5 minutes, it stalls. Sometimes it starts, sometimes it doesn't. If it sits long enough, it starts again.  Any idea what could be happening? The battery is charging when running, the gas is still coming out of the air box drain hose? The petcock and tank is ON, and the tank is filled up.  I am not getting any leaks from what I took off.

2007 Suzuki GS 500F

Do you have an in-line fuel filter?

Is that stock? I am not sure where to find that.

I am not sure if my petcock is hooked up right.. is this correct? All these diagrams I find dont match my petcock.

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Ah found this.. http://gstwins.com/gsboard/index.php?topic=61995.0

So I corrected it, but I still stalled out and got a few spats out of the air box.  Seemed better, gave me false hope, but eventually died and wouldn't start. brand new plugs, clean carb, fresh gas.. same issue.

Did you try running the bike on prime? You might have clogged tank vents or something similar.

Like these guys have said - but to make it more general - Hose routing ? float level ? and vent from tank and carbs are all suspects in your situation. Check those and post back.
Cool.
Buddha.

Gas coming out of the airbox drain hose... a couple issue with that.

First I'll get to what you came here for:  Your bike is flooding with gas.  One of two reasons or both... The floats are set to high, or your carb needles are at fault - carb needles could be stuck open, could be worn, etc... 

Now I'll get to the other issue, and why you will be glad you came here   :  Gas running out of the airbox drain means the carbs are letting gas through when its not supposed to.. which also means gas gets through to the airbox.. if enough gets through, gas will run into the engine.  Gas gets into your crankcase and now you are overfilled with 'oil/gas mixture'... this mixture no longer has its amazing properties of regular oil and loses its ability to lubricate the engine as it should... the GS engine is particularly susceptible to catastrophic failures with low lubrication situations... So, take home note - Check your oil! If its too high or smells like gas, you need to change it.  Obviously try to figure out the issue that is causing the gas to overflow first, so you don't wind up having to change the oil again.

- Bboy

Thanks.  This morning i turned it on cold, without choke, and it shot up to 5k instantly.  After 5 minutes, it dropped to about 3k (still really high.. especially no choke). It dropped to normal 1200 in a second.. sputtered for 30 seconds, died. My dad checked the vac lines and found a split. He replaced and is putting it together. I will see when I get home.

We had the carb a part once, and it looked good. No holes in the float or anything. I will review that next if this vac hose does not make a difference. Ill check oil last. I hope not as I changed oil end of fall before I put in shed!

suzuki shop here took it out when we dropped it off, and it died on him like me. They brought it back on a trailer and noticed the same issue. They took apart the carb and apparently all looked good, then re adjusted the valves, and put it back together. It runs without stalling now on the floor. Due to rain, he cant ride it now to test it but it seems to idle fine.

We will see when i pick it up tomorrow. I couldn't imagine valves causing the issue with gas going into airbox and what not would it? Maybe I pinched a line or hooked up a line wrong putting it together, maybe we didnt put carb back together tight enough, etc..  Ill see if it works tomorrow.

The bike seems to be fixed. 

A chain reaction of events caused multiple problems. It started out over the winter, when the carb varnished up. One of my floats probably got stuck. When I ran it, it shot gas into my airbox, in turn soaking my paper air filter. When we took apart the carb, cleaned it, and replaced it, we placed the same air filter in because no one in 100 mile radius seems to carry them. This caused the bike to choke out, not getting air.  Take out the air filter and it ran fine (except still kicking gas into airbox).

Solution: New filter


Second issue was the gas in the airbox still. Apparently, gas from this ordeal sent gas into my oil tank, which filled it up completely. So they replaced my oil.

Solution: New oil.

The stock air filter can survive a gas soak, in fact I wash it in gas to clean it. Just wash it outside to in (sorta angle a stream of gas from the tank like I do sometimes and get the stream to get out through the mouth, not hit the opposite wall) and dry it before installing.

Cool.
Buddha.

Humm that gives me an idea on how to run my 1/4 mile faster, soak filter in gas, and don't allow it to dry. Super cheap super sport bike for only a few dollars =) I'd be surprised if I was any slower than 4 seconds.


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