New Bike - Fuel Leak already!?

[sys49152]

Well this is really strange.. or maybe it's not (first bike, no experience with bikes at all).  Here's the deal :

I got my bike just this last monday.  I had no problems the first few trips out (clocked about 200 km's on it).  However, just two days ago, after riding for around 20 mins the bike felt like it was running out of gas.  I switced to REServe.. same problem -- the bike didn't feel the same ("bogging down", as mentioned in other posts).  So I put it back into the ON position.  Also, as soon as the revs dropped below 2000, the bike would stall.  I needed to keep the throttle slightly engaged during my trip home.  I filled up the tank just the day before, and confirmed that the tank was still almost entirely full.

After finally making it home, I noticed that a puddle of fuel, about the size of a CD, was sitting below the right side of the bike (slightly infront of the the rear break pedal).  Fuel would continue to drip if I managed to start the bike and reved it in neutral.  It also dripped out to the front part of the fairing.  I have a feeling that the final drip location on the ground might be misleading because of the fairings.  I wasn't smart enough that day to pull off the tank and check the fuel connections.  I did it the second day instead, but everything looked fine (as per Kerry's fuel hose diagrams).  Here's the kicker :

I started the bike up the next day, no problems!  Reved just right.  I took it for a spin and put on another 80 km's.  No problems again!  No bogging down, no stalls at low revs.  I parked it in the garage, and nothing leaked this time around.  I could however smell fuel, in fact the garage stinks like it, even though I don't see anything dripping.

I'm at a complete loss.  I think I'm going to take it to the dealer tomorrow since it's still covered.  The only thing I can really complain about now is the smell.. since the dealer will probably say "Hey, it doesn't leak now, so go home!".

I have to say, this is pretty frustrating.  I love the bike, but after reading post after post after post of fuel leak problems, carb float issues, petcock problems, etc, etc, I'm feeling a little shaky about my ability to take care of this bike.  300 km's on it, and I'm already comtemplating buying the parts/repair manual advertised on this site.

Side questions : would the Clymer Suzuki Gs500 Twins, 1989-2002[/i] be applicable to my 2004 GS500F?  I'm guessing that for the most part it would, but just wanted to confirm.



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[tdan553527]

That manual will work for you, the fairing, oil cooler, front forks, and some small wiring changes are the only things not covered in the book for the 04'

[airbrush]

I had a similar situation myself....first day i picked up my bike...got it home parked it...buddies noticed fuel dripping from the fairing and by the pedal...it was coming from the fuel overflow tube and running onto the fairing. Fired it up and let it run for a bit...eventually it stopped. Never had a problem with the bike bogging down though. Then a couple weeks later, i come out from work to find a big puddle under my bike...gas again...i start it up and immediately gas starts coming out of the tube...again...let it run for a bit and it stopped...never had the problem since? I suspect maybe it was a sticky float in the carbs?

[JamesG]

Since its a nearly new bike, it shouldn't have this problem. Take it back to the dealer and make them fuss with it.

[sys49152]

Jeff - yeah, I thought it might have been the overflow, but it definitely wasn't coming from that hose.  And it wouldn't have explained the stalling issue.

James - that's exactly what I did.  It's a national holiday today (Simcoe Day), but the dealership was open until 1pm.  They asked me to bring it in.  I got there at 11am, and they started working on it right away (kudos to them.. I thought they'd definitely blow me off today!) .  Diagnosis : not sure.. but the mech tightened the carb values ? - if you look at this diagram :

http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=723028&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=1999&model_dept_mfr=Suzuki&model_dept_id=703284&model_dept_name=GS500EX#stay

it's screw #13.  He said that they were tightened to spec before, but tightened them a bit more (still in spec).   He gave me a couple of pointers where to look if it happens again.

The bike was fine all the way home (about 50km's).  Is it just me, or does the bike aways give off fuel smell after any length of ride?  I apologies if it's a dumb question, but I have nothing to compare this with.