Suzuki GS500 Starting faults

HarrySheltz · L Plate Warrior Joined: 26 Jan 2021 Karma :

I have recently purchased a project GS500 (2006 MODEL).

It rusted in places, a lot of places and needs a lot of work. My main goal it to get it started.

I trickle charged the battery however I got absolutely nothing when turning the key in the ignition. No lights, nothing.

So I have purchased a new battery.

Not only that but the starter solenoid looks like it needs replacing. The Red fuse plugged into it looks damaged and is stuck into the solenoid so I'm pretty sure I need a new one of those but I have no idea what it is called or where to find one. I have attached a picture.

Also, the front brake calliper has no bolts so is essentially just hanging. Does anybody know what size bolts I need to secure it back to the brake disk?

Any advice would be very much appreciated. For reference the bike has been sitting for about 2 years.

steve the grease · Crazy Courier Joined: 26 Jan 2018 Karma :

There is no picture mate.
There is no chance that the battery would be any good after being stood for 2 years.
The question is, why is the front brake hanging? Is this the reason the bike was parked up, some one started a job and then lost heart, ( or maybe just the bolts!) possibly changing the front pads, or maybe the caliper was siezed? As there is a Haynes manual available, you should buy one. It would help a lot.

https://www.ebay.co.uk/p/1239500755

At least with an established brand there are spares available .

The front brake ( looks just like my DR250R)

https://www.cmsnl.com/suzuki-gs500f-2006-k6-usa-e03_model34237/partslist/BLCK0032.html
____________________
All the above is my personal opinion, you can see my lips move, but I'm talking out of my arse.
I've been riding, and fixing , bikes for 50 years, in that time the more I learn, the less I am absolutely sure of.....

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

If you have no electrical activity at all, check/replace the fuses. There is the main (usually 30A) fuse on the starter solenoid, and also another handful of fuses in the fuse box. Should be somewhere near the battery.

The brake caliper bolts are a particular grade of steel that is resistant to shearing or snapping. Get the right bolts from Suzuki, rather than just replacing them with something you find that fits. Cheap stainless bolts that fit are entirely the wrong thing to use, seeing as they are more likely to shear when you need them most.

HarrySheltz · L Plate Warrior Joined: 26 Jan 2021 Karma :

Thanks for the feedback guys.

I have re uploaded the picture.

I am very green to mechanical and electrical issues, this is my first project bike!

Its the red fuse you can see in the picture that is confusing me as to what it is.

oilyrag · Nova Slayer Joined: 07 Oct 2020 Karma :

The red part in your picture looks like a standard connector with an added cover for the fuse. If the connector is melted replace it. If you google gs500 starter relay connector you will see them for sale.

https://images-na.ssl-images-amazon.com/images/I/61-US5iW7DL._AC_SL1000_.jpg

oilyrag · Nova Slayer Joined: 07 Oct 2020 Karma :

In your picture. The thick wire is bolted to battery positive terminal and the other side of the thick wire is bolted to the starter relay. Inside the relay there's a connection from that thick wire to one side of the main fuse. The other side of the main fuse is connected to the thin red in the multi-pin connector. That thin red wire is the 12V feed for the rest of the bike. If you've got a blown main fuse or a bad connection inside the starter relay, or inside the multi-pin connector nothing will get 12V. Also if the ground cable going from the battery to the frame is not connected properly nothing will get power.