Got my first full hour of pottering done tonight (wife and baby asleep) found some interesting stuff. and good to at least locate things e.g float drain screws, ignition coil.

1. its listed as a 1993 but the plate says 1990 (administrative errors are commonplace here though)
2. tank has been repaired at least once (silver solder visible underneath)
3.  cleaned air filter (Thanks for the tip Buddha)
4. found perished fuel line.
5. Frame petcock is very loosely fastened by one bolt (is that right)
6. Air box is quite tricky to remove (seems to be sticking on the left side of the bike, the side with the fuel tap.
7. removing the tank also reminded me of an issue we had with the bike when I got it.  A horrible vibration from the fuel tank.  There was a stock rubber on the frame but also a piece of rubber garden hose on the tab of the tank that indexes into the frame.  Is there a factory part that does the same Job or is the garden hose a known fix for tank vibration?


checked my 5/16 line fits and it does but I think I'll invest in some uni clips.

Anyone offer some best practise tips for cleaning a "shredded" or for US helpers "barn bike" just don't want to go throwing water over all the exposed writing terminals.  Right now I'm on WD40 with some brushed and a rag after vacuuming and blowing off dust with compressed air.

Thank you all.
jimmy

Yes the one bolt on the petcock is correct as far as i know, and if you take off the frame petcock you'll have no problem getting the airbox out, it'll stick on that petcock if you don't. There is a rubber peice in the spot you're describing maybe if it was really worn out then the hose would fill the gap but I'd look for a new one, Good luck!

How terrible a job is a chain replacement?  I have the skills to change spark plugs, oil and air filters and have replaced a chainsaw chain.

My bikes chain is choked up with the fur from our Husky x Malamut and no amount of cleaning with spray and toothbrush is getting rid of it.  Can I soak it in Kerosene?

You can soak it in kerosene, but how bad is it? If it needs replaced, both sprockets should be replaced at the same time (they wear together). Taking the old chain off isn't a big deal since it can be cut off. But putting a new one on requires a special tool if you get a riveted master link.

Any info on tachometers? Will a 2003 taco fit on a 1990 bike?
Thanks

There was a change in the tach pickup (from mechanical to electric) at one point. I can't remember if it was 2002 or 2004 though. If the tach you're looking at has a mechanical cable hookup on the back side, it will work with your emgine.

We had mechanical tachs from 89-02 and electric ones from 04-09.  No 03 GSs were sold in US so I don't know for sure.  Look at ignition pick-ups under small 3 bolt round cover on right end of crank, if it has 2 coils it's mechanical and with a single coil it's electric.

http://img.photobucket.com/albums/v443/jcp8832/gs500signalgenerators_zps2134172a.jpg

dug out the tachometer.  Do have a new cable but its likely the gear inside the gauge thats at fault..Sending it to Adelaide Instrument Services to be reconditioned.  I other news I took off the chain guard and cleaned off about a decade worth of oil and scum.  Used an American Product from Scott which is used in Restaurants to clean grease traps etc.  Sprayed on and let it sit, scraped then sprayed with regular auto degreaser and submerged in tub of hot water.

Have exposed carries but am scared to death that I'll take them apart and not be able to put them back together.  Two rebuild kits are on their way from the USA (way cheaper than OZ). and will be doing the ring around for an oil filter somewhere in my area of the world.

so "wrenching" is underway.

in Fantastic news the battery we "stored" has been topped up with demineralised water and charged.  After sitting a week off charge its holding 12.4v RESULT!

Quote from: fakejimmymorgan on July 05, 2015, 05:45:12 PM

Have exposed carries but am scared to death that I'll take them apart and not be able to put them back together.  Two rebuild kits are on their way from the USA (way cheaper than OZ). and will be doing the ring around for an oil filter somewhere in my area of the world.

I don't know if it's from an auto correct error, or maybe different terminology down in OZ.... but what are "carries"? I would guess carbs, but just curious.

In regards to the oil filter: Suzuki used the exact same filter for literally decades on many different models so finding one shouldn't be too hard. The filler in my 1980 GS450 is the same as what's in your GS500 for instance.

well spotted auto-correct error. *forehead slap.

have downloaded the two carby cleaning videos from the net into my iPad and purchased more carb cleaner spray, paper towels and guitar strings.

Now just a small matter of light.  Need a floor so I can see what Im doing on the bench.  All in time I guess.

Bye for now.

have pulled the carbs and am not looking forward to reattaching the throttle cable.  took off the float bowls and jets, gave them all a nice long hot bath.  Boiled them up in citric acid (sort of) and went down the guitar string route to make sure they were clean.

New Diaphragms arrived  .  How bad are they to replace.  Not liking the idea of pulling more out of the carb.  Haven't checked the old ones yet.  Am I just looking for cracks?

The diaphragms are easy. Just watch for the small orings under each plastic cap (one in each carb).

sounds like I won't do them until the carb kits arrive then.

my carb kits arrived today.  Any hints to changing the float needle seat, is it screwed in?

Things were going swimmingly then this happened!!! Why did one needle have two plastic washer things and the other only have one?

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killing my own thread here but have put the needles back with the help of a carb rejecting tutorial from an angel fire page.  And kept the excess parts.  Swapped the o-rings, float needle seat and float needle as well as the float bowl gasket.  Thorough clean of course.  reconnected the throttle and choke cable but will need to check theyre adjusted correctly (Have no idea about that) and will have to study many diagrams about fuel hose routing as I have a few hoses that I vividly remember the location of and a few I have no fecking idea about. 

Theres one with an inline filter in the end that I think goes to the T piece at the bottom of the carbs as I believe it supplies the float bowls.  Theres one where the carbs meet the inlet ports thats routed through the middle of the two carbs that Im not sure of..... and many others.  will print the routing images in colour at work tomorrow.

But end result is progress.

battery is toast. Speedo cable was fouling on the top of the carbs and not letting the tank sit down.  Got smaller OD fuel line 1/4 and clips to attach and help routing it between airbox and frame. 

Assembled but no amount of charging will help the battery turn the bike over.  Ordered a new battery from All Purpose Batteries online $72 for gel type. Free delivery for orders over $20.

Quote from: fakejimmymorgan on July 15, 2015, 03:15:49 AM
Things were going swimmingly then this happened!!! Why did one needle have two plastic washer things and the other only have one?

Hey jimi, you need two of each of the plastic spaces. The smaller two go underneath the E clip ,one on each needle and the larger goes on top of the E clip. The spring on the diaphragm then holds the needles in place. It wouldn't be too hard to make one out of some suitable plastic