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**AOD** · 07-21-2003, 04:58 PM

i'd start by changing your clutch cable, or at least checking to make sure it moves freely. then do a clutch actuator adjustment (you need to buy a Clymers manual, or read my post about it in the post titled: GS450 Clutch Cover)

as for the warm starup issue...my new bike did that. it required me to crank it for 20 seconds sometime before it would fire again. this was caused by the engine coils being weaker when hot. new Dyna coils have solved the problem.

~Adam

**Anonymous** · 07-21-2003, 05:33 PM

Hi Adam,

At risk of sounding like a completely imcompetent novice, what did you mean by saying "making sure clutch cable moves freely" ? When I press the clutch lever, the cable does move, and the linkages it is connected to at the bottom move too, but not too much. My clutch is really stiff.

I have a Clymers, and will read abt the clutch actuator adjustment. I just wanted to be sure if I need to get a new clutch cable, trying to keep down expenses. I dont even know how much it would cost!

About the starting problem. I came home and tried starting it, but it doesnt start. I also notices that there was fuel dripping onto the floor from a pipe that comes out of the airbox(??) before the carbs. Also I noticed that when I tried to start it, there were some fizzing sounds from the combustion chambers. I checked the spark plugs and found them to be wet with gas(i think). So I;m guessing I've flooded the combustion chambers somehow with gas.

I'm at a loss what to do here. I'd greatly appreciate any advice.

Thanks

Anuj

**AOD** · 07-21-2003, 11:46 PM

if you're getting gas on the floor, turn your petcock from PRIME to the ON position. if that doesn't stop the problem, you have a stuck float needle valve...or the seat has gone bad on it. sometimes a cleaning may help the problem. the bike probably wont start because its overly rich.

as for checking the clutch cable moving freely...i mean remove the cable from the bike, or disconnect it from the clutch mechanism, and see if the cable slides freely. sometimes a simple bend or kink or pinch in the cable can cause it to be tighter then needed too. check the routing of the cable.

~Adam

**Anonymous** · 07-22-2003, 12:02 AM

if you're getting gas on the floor, turn your petcock from PRIME to the ON position. if that doesn't stop the problem, you have a stuck float needle valve...or the seat has gone bad on it. sometimes a cleaning may help the problem. the bike probably wont start because its overly rich.

Hi Adam,

Well, the petcock was in the ON position. I guess the major fuel leakage happened after I ran the bike for some time; the leak from that pipe has stopped now.

As I mentioned, I noticed that the spark plugs were wet with gas. I also noticed when I looked into the little oil indicator at the bottom of the bike, I cannot see the level of fuel, i.e. Theres no line at all. I just filled oil yesterday so I know It isnt empty, so i'm guessing its over full, probably with gas mixed in. Could that be a reason the spark plugs were wet and the bike is not starting.

I am planning to drain out the oil again and refill it. Also as you suggested I'm planning to clean my carbs.... have never done it and doesnt sound like a cakewalk... Hope it'll work good after that. Will letcha know. Thanks for your advice.

I'll check on the clutch cable and let you know if it slides freely. I did see that the linkages that the cable is attached to at the clutch housing moves freely i.e. swings left and right. Is it supposed to be that way. or is it supposed to be spring loaded?

Thanks for all your advice dude. Sorry for pestering you with my questions. Really appreciate all your help.

Anuj

**Anonymous** · 07-22-2003, 01:10 AM

Clutch: Adjust the clutch cable freeplay as your Clymer manual instructs. That is likely your problem. However, it is not unusual for a bike that has been sitting to have a slightly dragging clutch, but this usually goes away in a few seconds if properly adjusted.

Fuel: This sounds like the classic Suzuki bad petcock diaphram problem. Do a search of the forums for more info. Best fix (and peace of mind) is a new petcock. A bad petcock allows fuel to flow through the broken diaphram into the vacuum line when the bike is parked, and then to the number two cylinder intake tract where it causes fuel to enter the combustion chamber and the airbox. The fuel can contaminate the oil by seeping down the cylinder walls to the crankcase. This petcock problem can also cause cylinder number two to flood/foul as engine vacuum pulls raw, non-atomized fuel into the number two intake manifold as the engine runs.

A small amount of fuel in the oil is not a problem in the short term, it should safely boil off without any engine damage (SOP on small aircraft engines is to introduce fuel into the lubricating oil by way of a purpose-built pump/valve to thin the oil for starting when the weather is cold).

Too much fluid of any formulation in the crankcase is a bad idea! Balance the bike on two wheels, then tip the bike as necessary to gauge the oil level. If it is significantly higher than the "high" mark, you must lower the oil level by some means.

Again: If fuel is dripping from your airbox when the bike is parked and the petcock set to "on", then you almost certainly have a bad petcock.

**Anonymous** · 07-22-2003, 02:11 AM

Hi Al,

Thanks for your input. I was working on the clutch right now. Lemme describe what I observed.

The clutch cable slides freely within its housing. I'll probably still replace it as it looks kinda worn towards the end. The cable was probably not routed correctly: I pulled it off and rerouted it and reconnected it. Then I pulled in the clutch and put the bike in gear and tried rotating the rear wheel. The wheel turns, while in gear with the clutch pulled in (disengaged). I noticed the wheel turned easier in the 5th gear, and got progressively more difficult as I went down to the 1st gear. Is that normal, is it a good test? I didnt want to open up the clutch assembly. So I'm hoping that this means that the clutch is working okay. I'd appreciate your opinion on this.

About the petcock valve - Hmmmm.. This might get a little long-winded. When I bought the bike, the petcock was useless, so I found one from a salvage yard, and it looked good. I filled the tank with water and vinegar to wash it out and clean out some rust, and while it was full I tested the valve. On PRIME the "fuel"/water+vinegar flowed freely. On ON it didnt flow, but I sucked on the vacuum pipe and it flowed nicely. Same thing for RESERVE. So I thought the petcock worked fine. HOWEVER, right now I took the tank off, There wasn't much of a drip on the ON position. About a drop every 20 seconds. But I tried sucking on the vacuum tube (while on ON) and it didnt work, no gas came out. ????? Did the diaphragm go bad after I installed it?

I will clean out the oil/fuel in the crankcase and also clean out the carbs. I'd highly appreciate your inputs again. If replacing the petcock will help, man, I think i'll spring for it, altho' a stack one costs $60, and thats way above a brokeass grad students budget. :?

Anyways, thanks Al/Adam for your inputs. I just wanna get this bike on the road!!!!

I really appreciate your help.

Anuj

**AOD** · 07-22-2003, 09:47 AM

you might be able to find a petcock on ebay or another boneyard.

try taking yours off again and examinging it. make sure things look okay. maybe something is not right in there, and causing the problem.

**Anonymous** · 10-15-2003, 06:16 PM

hey there, little late, how's it going?

I might just be misreading your description of the clutch, but while you've got the lever pulled in it should roll freely in gear or neutral. :? It might have some slight resistance to spinning the wheel while in gear, and your desc of the progressive resistance going down the gears sound good (I think). it doesn't sound like it's doing anything it shouldn't...

The rest of the problem sounds like it's not getting enough gas to the carbs? could very well be your petcock, I think that's the most commonly used word on this forum!!! I took mine back apart last night and cleaned it all up, very thuroughly, then really took my time putting back together, we'll have to see if it really holds or I have to shoot it. :roll:

as for starting, I use spray ether (starter fluid at any corner gas station) to get mine started sometimes, take off the air filter and spray just a squirt toward the front airbox (the one that had gas pouring out the drain hose) then hit the starter. should gun right up for as long as the vapour lasts, but I find it to be a good way to get the engine "equilibrated" (at least blowing out anything in there, and hopefully pulling in some good things too!)

I will also say I am a complete newbie to these bikes, but I've been dealing with alot of these issues in the last few months!!!!

**nabrams** · 10-16-2003, 01:10 PM

see the following link:
http://www.thegsresources.com/_forum...ir+filter+carb

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Newbie - got my bike running, but it dies on me :(

Newbie - got my bike running, but it dies on me :(

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