building a GS500M+velorex562

[wouter]

Hello, I introduced myself here and i introduced the bike here i want to continue the story in the correct forum so here i am.

I picked up the GS500M last friday. It was sitting for more than 3 years in a shed. I payed 500€ for it. It has less than 20000km. The plan is to get it on the road, ride it this summer and mount a velorex 562 next winter.

Because i'm a little kid with a new toy i already started wrenching.

The bike did not run when i bought it. First thing i found was the tank was empty. Next thing i saw was bad fuel in the carb bowls.

So I wanted to clean the carbs. I removed the carbs from the bike. I had problems removing the cross vises from the rail. Becouse i didn't want to ruin them i stopped trying. I get the propper tools this weekend.
But i took all 4 the carb bowls of and cleaned them. I found the general condition of the carbs ok. I mounted the bowls back.

Whilst removing the carbs i saw one bad intake boot. One part was on the carb the other part was on the engine.

Like I said I'm like a little kid and i wanted to hear the engine run I . I putted everything back and tried to start.

The engine ran only on cyl 3 and 4. I did some investigation an found no fuel in the carbbowl from cyl 1 and there was a spark on cyl 1 and 2.


There is some more work to do. I'll remove the carbs back and dismantel them complete with the proper tools.
I already contacted (by mail) the local suzuki dealer. They don't know the GS500M type. I'll visit them next friday. I hope he can help me.

I'll try to take some pics this weekend and I'll to continue the story in this topic.

to be continued...

[Larry D]

Not sure if you've seen this, but, you carbs should cleaned in this manner. I really, really, really, would love to get my hands on a 650M. I didn't know there was a 500M until you posted the other day. I love me some baby Kats......

http://www.thegsresources.com/gs_carbrebuild.htm

[Tim Tom]

New rubber boots and good sealing o-rings will do wonders with these GS bikes. I don't know if you intend on having the local suzuki dealer try and fix it or not, but I have heard horror stories from 95% of people who let a shop work on their bike. Unless they are used to working on older bikes they have a high risk of doing something wrong and charging lots for it. Better to do it yourself I think.

Again that's just my 2 cents, you do what you feel is right for you.

PS I think your bike is cool

[katman]

WEcome and good luck on the work. Make sure you have a shop manual and with all the knowledge on this forum you should make out just fine.

[wouter]

@Larry D: Yes, i saw that procedure. That was the one I wanted to follow until some screws were to tight for my old screwdriver.

@Tim Tom: I'll fix the motor myself, I'll contacted the dealer to order parts.

@Katman: I have a manual from BikeCliff's website. I see there is a lot of knowledge on this forum, that was the first reason to register.

[wouter]

I borrowed my father in law his impact screw driver and removed all 4 intake boots. They are all crackeled and hard. I'm gonna replace them all together with the o-rings. That is what everybody is advising me and now I can inspect them better, it looks like a good idea . And i'll replace the cross screws with allenkey bolts.
I managed to get the carbs appart. The cyl 1 carb is totally dismanteled. Most of the holes are blocked and the fuel inlet pin was stuck.
Tomorrow i'll go shopping.

[wouter]

Went to the suzuki dealer and ordered the intake boots and O-rings yesterday.
A friend of me has a shop where he sells and repairs garden machines. I helped him for several years during the busy periods. I know he has a big collection of o-rings. I went there with the dismanteld carb and he had al the o-rings i need to rebuild the carbs. He only charged me 5€.
He also offered me to use his ultrasone machine to clean the carbs.
Next monday is gonna be carb ultrasone and rebuild day.

[wouter]

Here are some pics of the bike.

[wouter]

Today I changed thebrake oil. You can see in the pic the old oil. Just in time .



I'm glad i followed the advice of BassCliff and waterman and change the oil first.
This is a 5liter can. and that wasn't all. I think some fuel was in there too.



And here are the carbs before and after the ultasone.









Some mechanic did a great job in the past. I removed the rear wheel to clean. The axle and stuff was all covered in grease.

I decided to remove the exhaust so it was easier to clean it. To my surprise the exhaust bolts came off without any effort.
The 4into1 with boss muffler. It looks a lot cleaner now. (no pic yet)

It was a productive day.

[Charlie G]

wouter,

If you suspect that there is fuel in the oil, check to see that the petcock (fuel tap) is working properly. You work is looking good.

Charlie G

[wouter]

wouter,

If you suspect that there is fuel in the oil, check to see that the petcock (fuel tap) is working properly. You work is looking good.

Charlie G

Thanks for the advise.
Yes, i checked the petcock when i took the tank off. There is now 5liter fuel in the tank and it is not leaking with the petcock in "on".
I think the seller left it too long on "pri" when trying to start the motor.
Now i know how he managed to get the tank comletely empty .

[wouter]

I finished the carbs today.
Ready for the summer.





I know, some parts were not mounted when i took the pics, but they are now.

[Smokinapankake]

Good work. Will be watching with interest. I really like the smaller Katana's.

[wouter]

This morning i picked up the intake boots, o-rings and some other stuff i ordered.
I mounted everything and tried to start.
After some starting and putting the petcock in different positions (there is only little fuel in the tank) it ran. I rode it out of the garage.
It was idling around 3000rpm. It took a minute before i realised i could adjust that.
So i set the idle to a normal rpm.
That was it for today.
Can't wait till tomorrow, maybe a little tour around the block

[Charlie G]

I was wondering how you were doing on the bike. Glad to hear it started up for you. I hope there sunny skys for tomarrow.

cg