2004 suzuki gs500 losing power.

[DanUK]

Hello, i have a 2004 suzuki gs500 with a power problem. I recently purchased this bike with only 4500 miles on the clock, the guy said it had been sat around for a year gathering dust. It looked in good condition but had a few splits in the fuel lines. It started up fine, bit of erratic idling but nothing major. I took it for a test ride and it was bogging down, i thought that would be due to the split in the fuel lines and sucking air etc. so i changed the fuel lines and now it doesnt lose as much power but still quite a bit.

When i start it up it starts up fine, and i can wind back the throttle and it goes up the rev band nicely.

As soon as i get on the bike and go for a ride i wind back the throttle and it accelerates for a split second and then loses power at about 2-3k revs and then goes very slowly up the rest.

It has a restrictor kit on it but i have no idea whether its fitted properly or not, could it be this? if so what can i do about it?

My other idea is, could it be compression related?

Or is it something to do with the carbs, are they not set up right, putting to much fuel in ?

I took both spark plugs out to have a look at them and found them to be quite black with the inner prong being white on the tip? no idea whether this helps?

also today as i was replacing the perished fule hoses i removed the air box to make it easier, i say the slide in the back of the carbs, when i twisted the throttle they didnt move, could have sworn that no all my old bikes they moved, something wrong there?

Any ideas would be great thanks.
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2004 suzuki gs500

[N cee thirty]

to say its been stood for a year,have you serviced it ?

new plugs,oil,filters etc

maybe the carbs could do with being balanced
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[DanUK]

its got new oil in it, new plugs, havnt changed the filter though
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2004 suzuki gs500

[Scotsman37]

Good idea is to give the carbs an overhaul as the jets are probably clogged up with crap giving you possible idling/acceleration problems from being left sitting around for a year!!!

[DanUK]

okay so ill try and take the carbs off and give them a clean, whats the best way to clean them?
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2004 suzuki gs500

[Scotsman37]

After removing the carbs ( disconnect the fuel line and run engine till it dies to use up as much of the fuel in the carbs as much as possible) and use a decent quality can of carb cleaner along with a can of compressed air to blow the crap out, but if is still remains clogged using something like a 'E' string electric guitar wire as it's slim but strong enough to break through the crap!

[DanUK]

okay ill give it a go tomorrow hopefully.
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2004 suzuki gs500

[Pete.]

First thing to do is take the fuel feed off the carb and see that it flows consistently. If it does you need to have the carb off, if it doesn't, check for a fuel filter in the tap or the tank.

If your fuel tap has two lines to it - one large and one small - you'll need to suck on the small one to make fuel flow from the tap.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[DanUK]

okay so i took the tank, seat and airbox off today to get to the carbs to take them off for cleaning. (checked the fuel lines to make sure petrol flowed, and it did. so decided to take the carbs off) i started the bike up with the airbox off to make sure the slides worked and to use up the petrol in the float chamber. After i started it up i gave it some throttle and an explosion occured in the right carb?? guess this isnt meant to happen, after this i turned it off. I continued to take off the carbs. the problem is someone has obviously played with the carbs before as EVERY screw on the carbs is rounded off..

Any ideas? do i need to buy new carbs? i see some on ebay but there for the 2004 gs500 f model, mines the 2004 gs500, is the only difference the fairing? if so there on there for £68 inc postage, should i buy that and fit them?
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2004 suzuki gs500

[fiery tupp]

I'd try to get them apart somehow & get new screws , etc.
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If you can't fix it with a hammer , use your head .

[Scotsman37]

You could try buying or getting use of an impact driver to help remove the screws or possibly as the carbs are now off and don;t have an impact nor the replacement screws maybe you could take it to your nearest bike mechanic that has the appropriate tools to remove the screws and hopefully he will have at hand replacement screws and have him clean the carbs for you instead. This all depends on the cost of this being done for you or trying it yourself?

[DanUK]

okay, i think i will have a go at getting the screws undone and then clean it and replace the screws. ill let you know how it goes.
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2004 suzuki gs500

[DanUK]

forgot to mention, when taking off the carbs i didnt find any washers restricting the bike.. good honest guy who sold it to me then
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2004 suzuki gs500

[hmmmnz]

they quite often don't restrict the gs with washers,
normally its done on the slide,
if i remember rightly its got an extra hole
i'll try and find a pic at some stage,

clean the carbs out, reset the mixure screws, balance the carbs by eye
or by using a thin part of wire,

make sure the butterfly shuts at exactly the same time with the same gap,
thats normally as close as you'll get it even with balancers, if the bikes engine is sweet,

make sure the vacum hose doesnt have any splits, if it does it'll be sucking more air into the top of 1 carb and restricting the fuel flow from the fuel tap
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the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[Odie]

also make sure the fuel lines (all 4 of them) go back in the right place on the second fuel tap, had a GS500 and some-one had played with them and it ran like like a bag of shit
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You are so ugly when you were born the doctor said "I?m gonna drop it, if it falls is a rat, if it flies is a bat."

[DanUK]

okay thanks, are the mixture screws behind the brass blanker things? And does any1 know what the default settings are/ would i find them in the haynes manual, (currently biddin g on one on ebay) Also a pic of the slides would be great, i looked at the slides and they didnt have any holes in. although the bottom of the slides were curved allowing a small gap when closed.

So im guessing it sounds like a fueling problem then and not somethign to do with the compression etc?

Thanks for the help.
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2004 suzuki gs500

[Scotsman37]

Carb setup

Just unscrew the brass caps and just screw it back on when finished.

Could you see a perfect circle of light coming through the jets (brass caps that are screwed in) and if not then they are clogged. Also, did you blow carb cleaner and compress air through the small openings?

Image of carbs

[DanUK]

okay so i managed to get all the screws undone on the carb and took them apart, i looked at the jets in each carb and realised someone had put the jets in one of the carb the wrong way round. They swapped the main jet for the middle size one (dont no what that one is called) So the main jet had a smaller hole than the middle sized one, where as the other carb jets seemed fine. Could this have caused the problems i was getting? i Have yet to get the bolts to put the carbs back together but when i do (hopefully tomorrow) i will let you know what happened. Also whats the default setting for the mixture screws, is it 2.5 turns?
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2004 suzuki gs500

[fiery tupp]

It would be worth checking , before any adjustment of the mix screws to count how many turns in they go now & remember where you started from.
So you can allways go back to the original settings , if you have to .
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If you can't fix it with a hammer , use your head .

[DanUK]

okay so iput the carb back together and put it on today and it still didnt run right, i realised it was actually only running on one cylinder. The running cylinders spark plug was getting black but the non running one was still shiny. Thing is when the bike was running (on 1 cylinder) my dad sprayed easy start into the back of the non running cylinders carb, it then fire up for a moment and the bike sounded fine. Therefore there must be a spark and compression. It must just not be getting fuel?
How can one cylinder be getting fuel but the other not?

so i thought it must be the carbs again, so i took them off and took them apart again, i took out the jet needle and found that a spring was missing from between the neeled and the plastic bit that holds it in place. Also i compared the needle lengths before i took them out and one was slightly longer than the other, could this be the problem?

I now need to locate a new spring, any idea on where i can find one? Thanks Dan.
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2004 suzuki gs500

[Scotsman37]

https://webservices.motorsportdealers.com/parts/partImages/SUZ/2/02/198/0013.Gif

https://www.cmsnl.com/suzuki-gs500-f-2004-2006-usa_model16027/partslist/300549.html

[DanUK]

thanks although they want a minimum order of 10 euros , so 10 euros for a spring bit expensive, ill tyr local bike store tomorrow if not, 10 euros it is.
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2004 suzuki gs500

[Scotsman37]

[DanUK]

okay so i took apart a pen and found a spring very similar to the one i needed, i cut it to size and used it in the carb, put it all back together and hurrah! it started up firing on both cylinders, then i took it for a ride and it ran full power excellent! who would have thought that such a small spring would make so much difference! Thanks for the help
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2004 suzuki gs500

[Scotsman37]