from my notes,

I had good luck with Motion pro hoses but most folks like the OEM ones as there is not much space..

"Fuel hose = (tank water drain is the same) 8mm (5/16) id. - 11.5mm (7/16) od.  Need 1.5m for whole bike"

I think for the most part I figured out the two petcocks. the one in the tank is just reserve and main. The other has places for them. The one on the front is for the foam. The one behind that, Im pretty sure is for expresso. So Im pretty clued in on that. What I am having issue is hose size. I noticed two sizes. Im pretty sure the smaller size is 6mm. What is the other size one (metric) I want to get a proper fit. Cant have leaks in my expresso/GS500 machine.

The 2-valve GS1100 was a popular platform for drag bikes, you would need to check spec's for the wrist-pin etc

In the service manual, 2003 is the year they introduced the updated ignition system with the electronic tach. It's probably closest to a 2004 in terms of ECU, harness and carbs. They were jetted a little leaner with a 127.5 main instead of the 130.

Sorry to hear that buddha, thinking of you and wishing you strength.

Yea Mr72 is right. 40 non bleed pilots are what the Dr Bob ordered.
And no The air screws work all the way to maybe 5 or 6 out. Then you run the risk of them falling out.
Cool.
Buddha.

Quote from: cbrfxr67 on September 20, 2023, 10:11:33 AMDangit I just came here to see what Buddha's answer was and nothing,... So disappointed.

My ears were burning.
I have been busy getting divorced and working 48-64 hrs a week to pay for divorce etc.
Cool.
Buddha.

Quote from: herennow on September 22, 2023, 12:38:50 PMHi Keith, Ive got a 2003 Canadian model. You are right parts can be a bit confusing, I normally go with 2002 parts as 2004 had all the evap stuff that confused everything. Hit me up for specific questions. I completely rebuilt my bike from the crank up in about 20010 so have lots of leads.

These guys seem to be the only place I know that have a proper 2003 catalogue of parts.

https://www.christensensmotorcycles.com.au/partFinder/fiche/suzuki/2003/gs500#content

Unfortunately I had a SMIDSY experience last month (sorry mate, i did not see you) when an idiot turned RIGHT in front of me. Luckily I got away really lightly but the bike has bent forks broken pedal and levers and a broken rear plastic cowl.  Just got news from the police that the idiot is 'officially" to blame so his insurance will pay for everything (including my gear). I'm wondering whether to take the money and fix her up or possibly to upgrade.... She is just such a fun bike to ride her in the twisties....

That's interesting to learn that Canada had a 2003 model. So they were  made in Spain but with 2002 parts? That's extra weird. Maybe Canada was the world's guinea pig for the Spanish assembly line.

I would do what I did with the insurance money after they totaled my bike. Buy it back, fix what you need to, and use the remaining money for whatever makes the most sense in your life. I was able to buy the "totaled" bike from insurance for around $500. I used the remaining payout to do a top end rebuild rather than fix the cosmetics that were damaged when a lady in a Jeep wrangler backed into my bike. Yes, I'm now driving around a near valueless GS500 with a salvage title, but it already had basically no value and its worth a lot to me and I got a fresh engine rebuild out of it.  I just hope nobody ever hits the bike again.

I managed to hit the ton once but that was about the limit, 180 to 200 seems a bit "aspirational"

Hi Keith, Ive got a 2003 Canadian model. You are right parts can be a bit confusing, I normally go with 2002 parts as 2004 had all the evap stuff that confused everything. Hit me up for specific questions. I completely rebuilt my bike from the crank up in about 20010 so have lots of leads.

These guys seem to be the only place I know that have a proper 2003 catalogue of parts.

https://www.christensensmotorcycles.com.au/partFinder/fiche/suzuki/2003/gs500#content

Unfortunately I had a SMIDSY experience last month (sorry mate, i did not see you) when an idiot turned RIGHT in front of me. Luckily I got away really lightly but the bike has bent forks broken pedal and levers and a broken rear plastic cowl.  Just got news from the police that the idiot is 'officially" to blame so his insurance will pay for everything (including my gear). I'm wondering whether to take the money and fix her up or possibly to upgrade.... She is just such a fun bike to ride her in the twisties....