well, first let me say that I got my ass kicked by my bike today.  I have been putting off rejetting and installing a new CRF petcock for about a week and finally got the nerve to do it this afternoon.  I followed all of the steps listed in the "poor man's guide to rejetting" from the Wiki.  I got to the part where I open the bowls and install the new jets.  I come to find that a PO has stripped one of the bowl screws so badly that I can't open it.  So I was able to add a washer to the needles but not able to install the new jets   If anyone needs one of Buddha's rejet kits let me know since I have a complete unused set for sale now.  So I started to put everything back together and install the new petcock.  I was able to reseat both the carbs and the airbox.  BTW, the stock airbox is the biggest POS anyone has ever invesnted.  The creator should commit hari kari because of this IMHO.  I run new fuel lines from the on and reserve nipples on the tank to the CRF petcock and a line to the bottom T connection of the carbs.  I wasn't able to plug the vacuum nipple on the carbs since I couldnt find it.  I turned both of the petcocks on and tried to start her up.  It tried to turn but would stop and starting clicking.  I'm pretty sure that everything is reseated correctly and the hoses are nice and tight.  I can't figure out what is wrong so I'm going to give it another go this weekend.  Anyone able to tell me what may be the problem?

I also have some questions since I got to see everything up close and personal.

1. what is the electric thing on right side of carbs?  It looks like some kind of connector to an electrical system, but I have no idea what it is.

2. where exactly is the vacuum hose on left carb?  I couldn't find it and cap it, which I think may be the problem.

Vise grips will get the bowl screws off i had to remove 3 of mine that way. don't give up GET THEM!!!

Thanks Mdow, I'll try that this weekend.  Any ideas on the other stuff anyone?

I don't know how much of a difference this makes, but it seems that the carbs I have are off a newer bike.  I have a throttle valve on my right carb and it also doesn't have those tiny o-rings under the caps.  I have no idea if that changes what could be wrong with it still.

Here's a link to what they look like - http://www.bikebandit.com/suzuki-motorcycle-gs500f-2006/o/m9752

You stuffed one of the 89-00 washers under the needle of a 06 carb did you ...
OK here is your sign ... put down the vice grips and blow torch ... and step away from the bike ...
The 89-00 washer is far too large to get into the hole the needle sits in on a 04+ carb ... you also need different jets and pilots and ... well everything is different.
I'd just say send me the carbs and jet pack, I'll credit you for the jet pack unless you chewed up some more of the jets etc ... swap to the 04+ jets right for your setup and set all the other screw ups back to normal and send it back.
I dunno why people think swapping carbs is the answer to all their problems ... trouble shooting is easier ... a lot easier.
Cool.
Buddha.

to be honest I had no idea that I had a new model of carbs on there until I took everything apart yesterday.  I did notice that the washers you sent didn't fit very well so I didn't use them.  I didn't get to use anything in the jet kit that you sent.

How much to send the carbs and jet kit to you and get them jetted and configured properly?

For 01+ carbs $50 + return shipping and you get 20 bucks credit for the jetpack.
And you have to write your setup in a note along with the carbs ...
Cool.
Buddha.

woops; buddha i dont think i wrote a note with mine. it was just through PM


i hope it still works 

Yea it works ... I am not that organised, but sorta semi functional ...
Your bolts for the brace to fender you gonna have to buy em ... they are not here yet ... crazies ...
Cool.
Buddha.