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GS850 Fuel pouring out of the port on top of the motor that connects to the airbox

  • Thread starter Thread starter mysundurstud
  • Start date Start date
M

mysundurstud

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So I have been offered a 1982 Suzuki GS850 for free. The catch is I have to get it running. Owner told me carbs were dumping fuel. After getting the carbs cleaned and put back together with the help of his friend Matt we fire it up and it is dumping a fuel/oil mix from the top of the motor. It appears to be a port that connects to the top of the air box via a rubber hose. I am looking for anyone who may have any knowledge. I am beyond my realm of knowledge and will be searching forums all night and then trying to fix it tomorrow by myself (which should be interesting). Any advice would be greatly appreciated.
 
If you have fuel pouring out that hole, ... STOP.

The only way fuel can be coming out that port is if the entire engine is full of gas, meaning you have some SERIOUS problems.
That port is a vent that removes any combustion blow-by fumes and sends them back through the engine to be burnt.

It is possible that someone has connected fuel lines incorrectly to cause this, but you need to drain the oil (and fuel) from the engine, put fresh oil in, then start from scratch.

Please post your location, one of us is probably close enough to lend a hand.

.
 
I am located in West Bend WI. Draining and starting over is where I was going to start this morning. I was reading how if the petcock was stuck and fuel was draining the whole time it sat, which was over a year, that fuel could have gotten into the crank case. SOOOO I will start by draining, refilling, running, re draining to get residual fuel out of the crank case, refill and see where we are at.
 
Time for a little maintenance eh? Best to take care of a few things before something gets damaged.

Check the Newbie Mistakes thread linked in my signature.
 
Thanks Ed. Tons of great info there. I will take the advice!
 
Not COULD HAVE!!! It DID fill the crank case. Get a new p[etcock right off. Have two or three drain apns at the ready or be real quick at getting the drain plug back in as the pan fills. Likely to be 3 or 4 gallons of liquid in there.
 
Had the same thing happen to me when I brought back to life my 1100G, only started it long enough to confirm that it would run. I drained 2 1/2 gallons of gas and oil out of the crank case. Refilled and changed again after about 20 miles. Oil stays pretty clean for the first few hundred now.

V
 
And, ... Before you crank the engine, pull the spark plugs.

If the cylinders are full, too, they will hydrolock, possibly causing damage.

.
 
If there's as much gas as I think there is, you need to be very careful when cranking it over. Disable the ignition before you try to crank it with the plugs out or you might ignite the gas that's going to be spewing out of the cylinders. In fact, I'd turn it over by hand with the plugs removed and the ignition off first. Once you've completed a couple of cycles, and wiped up what came out, you should be able to put the plugs back in and crank it over.
 
Thanks to everyone for the help. I cleared out almost 2 gallons of oil/fuel. Changed the oil. Ran it. Changed it again. Was about to test ride it and as soon I drop it into first gear, it shuts off. Any ideas?
 
Start at the beginning, adjust valves, Did you dip each carb at least overnight with all jets and rubber pieces out> Poke all the holes with fine wire and blow em out? If not you need to clean them again. Check the links at the bottom of Nessiem's post. Did you replace the O rings behind the carb mount boots, they are probably 33 years old and shot.

Bench sync after all the above, set your pilot needles to 2 1/2 turns out from lightly seated, they are the ones under the holes that have plugs in them that are on top of the carb throat that plugs into the mount, if they haven't already been removed, they should have and the needles removed and cleaned and O rings replaced.

That setting should get you running if your floats are set right. Now you can put a set of vacuum gauges on the carbs and do a proper sync.

V
 
Does it have a side stand switch? Was the stand down or is the switch working..if it has one??
 
chuck hahn said:
Does it have a side stand switch? Was the stand down or is the switch working..if it has one??
Click to expand...

The switch on the side stand has NOTHING to do with whether the bike runs or not.

It only turns on the light on the instrument panel.

There is no ignition cut-out, nothing, nada, that is connected to that switch.

.
 
More likely the clutch plates are stuck together from sitting . Dropping it into gear just killed the engine...
But there are more things to do here ...
 
Yes allot more stuff to do. Ask me how I know :)
Since your crank case was full of gas/oil you carbs over flowed.
Your floats and/or pins are the cause.

If it's been sitting collecting dust for a long time, you will have no choice but to clean / rebuild your carbs. Do not skimp out on this.
Even if you do skip this, if you want your bike to run right, you will be forced in the near future to do it.

You got your self an old bike with unknown condition, prepare your self for allot of fun and exciting challenges :).
 
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Actually c&c, the petcock is the primary shut off and if that fails the secondary ( and very temporary ) safegaurd is the floats and needles. Peretcly fine needles and floats will allow fuel to ever so slowly weep poast them under the fuels weight building perssure against them. And eventully the bowls fill and fuel runs down the venturis into the cylinders..and then the fuel goes past he rings and fills the crankcase.

Granted the needles and floats should be checked, but the first..and most responsible.. componet for FULL unquestioned fuel shut off is the petcock.
 
Interesting.
The fuel flow by must be very very low.
But as the tank empty's it's self the pressure drops... Humm.
 
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It doesnt take much to overflow the needles and carbs really. It wont happen in a day. But sitting over some extended time with the petcock allowing fuel to leak down sure will fill the crankcase. Which is why we advicate dont leave it on the PRIme setting too. Its my thoughts that is why the petcock is designed as the very closest thing to the tank to exercise fuel control. And if the tanks vent is clogged and the tank is in aheated up condition like being in direct sunlight, coupled, with the petcock isuue, a tank is pressurised even greater. Ever take a cap off and get a hit of air pressure from the tank?? Pressure built up from it not venting and subjected to some heat sours\ce such as engine heat, sun, heated gargae inn the winter....that sort of thing??
 
Thanks again to everyone who helped. The bike is running well. I adjusted the clutch cable because when I pulled the clutch lever in it seemed to lack tension. Due to the owner storing it with gas in the tank for well over a year, it appears that it flooded the carbs and the air box, leaving the only place for the fuel to go, the motor itself through the petcock vacuum line. I had to rebuild the carbs (they needed to be done anyway as they were really gummed up) drained the crankcase, put in fresh oil, ran it, changed the oil and filter again. Seems to be good to go. Still needs new plugs and a tach cable but Im riding again after 2 years and it feels amazing!!
 
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