Hello All!

I've had a lot of trouble with the carbs that were on the bike when I bought it including a very weird needle assembly. I've had the bike running on and off again (currently it hasn't been run for several months) but I found a set of mint-condition carbs from a 90s GS500 for cheap.

I have both the carb boots and the associated air box with these carbs so the difference in size of the intake and airbox boots is a non-issue. However, I believe the throttle assembly needs to be swapped out? I can probably figure this out as I tear the bike apart but I figured I'd first check here to see if there was anything I should be aware of going in.

Most importantly, I bought this as a project bike for very cheap after someone tried to convert it to a cafe racer. He had installed what looks like a clip-on exhaust. I'm wondering how this changes the equation. Does this mean I need to rejet the 90s carb? Should I be concerned about the pilot needle setting?

Thanks for any help!

just a different exhaust won't require you to rejet but if you are installing carbs from 25+ years ago who knows what jets are in them. I'd go through the carbs and rejet anyway. Depending on the exhaust probably you can go with 125 main jet and a 40 pilot. Be sure you have the stock (aluminum) needles. I'd replace o-rings and all that jazz before putting them on the bike. Save yourself a lot of time.

Make your life easy and stick with the stock airbox and paper air filter

Quote from: restless on July 30, 2019, 06:40:56 AM
However, I believe the throttle assembly needs to be swapped out? I can probably figure this out as I tear the bike apart but I figured I'd first check here to see if there was anything I should be aware of going in.

Maybe someone else who knows more about this specific thing can chime in with more info if I'm wrong, but I don't believe the throttle position sensor was introduced until 04, so I don't think that you'll need to swap out the throttle assembly for your 01 model.

There is no real TPS on this bike that does much of anything.
89-00 carb onto later bike = piece of cake. 01+ carb on 89-00 is a bit harder. You need the twin throttle cable setup. And the airbox doesn't fit the older carbs too well.
Manifold boots are also a bit of a poor fit onto the 89-00 carbs, but you cant find the 89-00 carb boots anymore, so you're screwed either way. Either now, or when you have to replace intake boots. Not too bad, manageable.
Cool.
Buddha.