Wednesday, June 29, 2011

GS500 Air Filter Replacement or Cleaning

Cleaning the air filter can help prolong the life of the engine in your motorcycle. This post document replacing the air filter on a 2007 Suzuki GS500F. The same procedure applies for cleaning. Suzuki recommends cleaning the air filter every 2,000 miles and replacing it every 7,500 miles or two years. The gas tank needs to be removed to change or clean the air filter.

GS500 Air Filter Replacement

The tools I used:
GS500 Air Filter Replacement

1) Put the motorcycle on the center stand to make it more stable.
GS500 Air Filter Replacement

2) Remove the seat. Turn the key while lifting up on the rear of the seat.
GS500 Air Filter Replacement
GS500 Air Filter Replacement

Seat removed:
GS500 Air Filter Replacement

3) Ensure the fuel petcock is turned on and the fuel cover on the tank is secure. The fuel tap is under the tank, and will be turned off in step 6.
GS500 Air Filter Replacement

4) Use the 12mm socket and ratchet to remove the two bolts, each one securing either side of the tank.
GS500 Air Filter Replacement

5) Gently lift up on the rear of the tank and slip a piece of wood to support it.
GS500 Air Filter Replacement

6) From the right side of the bike looking towards the left, the fuel tap is visible under the tank.

GS500 Air Filter Replacement

Use a flatbladed screw driver to turn the fuel tap from on (vertical) to off (horizontal)
GS500 Air Filter Replacement

7) Using the pliers, loosen the two hose clamps and remove the fuel hoses from the fuel tap. Make a note of which hose goes where. I used a zip tie to mark one side.
GS500 Air Filter Replacement

Have a rag handy to catch the couple drips of gas that will be in the hoses.
GS500 Air Filter Replacement

8) Remove the water drain hose
GS500 Air Filter Replacement

All three hoses removed:
GS500 Air Filter Replacement

9) Now that the tank is free of the hoses, lift up on the rear of the tank and pull towards the back of the bike slightly. The tank should come free easily. Place in a safe place.
GS500 Air Filter Replacement

10) The air filter is held by four Philips screws. Use the Philips screwdriver to remove them.
GS500 Air Filter Replacement

Note the two clips also held the the bottom two screws:
GS500 Air Filter Replacement

11) Remove the air filter
GS500 Air Filter Replacement

12) If cleaning use compressed air to blow it clean. This one is a bit dirty.
GS500 Air Filter Replacement

13) The Old (left) and New (right)
GS500 Air Filter Replacement

14) Install the new filter and replace the four screws. Remember the two cable clips on the bottom.
GS500 Air Filter Replacement

15) Reinstall the gas tank and reconnect the three hoses.
16) Remember to turn the fuel tap back to the on or vertical position.
17) There is no specified torque for the two rear 12mm bolts.
18) Go for a ride!

Other GS500 Guides/Howtos:

Monday, June 27, 2011

Playing with my WR250R Off-road

Playing with my WR250R off-road

I finally had the chance to get play off-road this year. Yes, I know I rode my Ural on many frozen lakes which is also off-road, but that was three wheels. It was nice to get out in the forest on a bike. I quickly realized two things. One, I am out of shape and was out of breath way to fast. Two, I am way out of practice which caused number one.

Playing with my WR250R off-road

I wasn’t very efficient or relaxed at first. After a few minutes of riding standing up, I became more relaxed. I still wasn’t very efficient which contributed greatly to getting tired too quickly!

Playing with my WR250R off-road

I was wearing my Alpinestars S-MX Bionic armor underneath my Tourmaster coat (with the armor removed). I think after I get to the forest next time, I will find a way to strap my road-coat to the back of the bike, maybe with a bungee net. I got pretty overheated even though I had all my vents open and it was only 75F.

There was a lot of water around, and many of the trails were under water.

Playing with my WR250R off-road

I rode for about an hour, and then I headed home exhausted with a big grin.

I acquired a bunch of mud, so I gave the WR its first bath of the year too.

Playing with my WR250R off-road Playing with my WR250R off-road

Enjoy the short video I made of the day:

YouTube Video: Playing with my WR250R Off-road

Sunday, June 26, 2011

GS500 Spark Plug Replacement

This post documents replacing the spark plugs on a 2007 Suzuki GS500F. This is very easy to do on the GS500 since the plugs are exposed. Suzuki recommends checking the electrode gap clearance every 4,000 miles or 12 months. Suzuki also recommends replacing the spark plugs every 7,500 miles or every two years. The correct electrode gap is between 0.8mm and 0.9mm. The recommended plug is: NGK DPR8EA-9. The GS500 needs two, one for each cylinder.

GS500 Spark Plug Replacement

The tools I used:
GS500 Spark Plug Replacement

1) Put the motorcycle on the center stand to make it more stable
GS500 Gas Tank Removal

2) Carefully pull the spark plug boot off of the top of the plug.
GS500 Spark Plug Replacement
Boot removed and spark plug exposed:
GS500 Spark Plug Replacement

3) Then use compressed air or a rag to clean around the base of the spark plug.

4) Using an 18mm deep socket or spark plug wrench, remove the spark plug
GS500 Spark Plug Replacement

The old (left) vs. the new (right). The gap on the old is over 0.9mm and out of spec. The electrode also appears a bit worn.
GS500 Spark Plug Replacement

5) Check the electrode gap on the new NGK DPR8EA-9. It should be between 0.8-0.9mm.
GS500 Spark Plug Replacement

6) I added a very small amount of anti-seize lubricant on the threads of the spark plug to make it easier to remove in the future.
GS500 Spark Plug Replacement

7) Hand tighten the plug and then use the wrench another 1/4-1/2 turn. The engine is made of aluminum and it could easily damage by over tightening.
GS500 Spark Plug Replacement

8) I used a small amount of dielectric grease on the end of the spark plug to prevent corrosion.
GS500 Spark Plug Replacement
GS500 Spark Plug Replacement

9) Attach the spark plug boot and ensure it fits snuggly.
GS500 Spark Plug Replacement

10) Repeat on the other side.

11) Go for a ride!

Other GS500 Guides/Howtos:

Saturday, June 25, 2011

GS500 Gas Tank Removal

The GS500 gas tank can easily be removed in just a few minutes with minimal tools. The tank does not need to be empty to remove it. The tank needs to be removed to clean or replace the air filter, check or adjust the valves, or adjust or clean the carburetors. This post will document removing the tank on a 2007 Suzuki GS500F with the fairing already removed. On some GS500s, the side panels may also need to be removed.

GS500 Gas Tank Removal

The tools I used:
GS500 Gas Tank Removal

1) Put the motorcycle on the center stand to make it more stable.
GS500 Gas Tank Removal

2) Remove the seat. Turn the key while lifting up on the rear of the seat.
GS500 Gas Tank Removal
GS500 Gas Tank Removal

Seat removed:
GS500 Gas Tank Removal

3) Ensure the fuel petcock is turned on and the fuel cover on the tank is secure. The actual fuel tap is under the tank and will be turned off in step 6.
GS500 Gas Tank Removal

4) Use the 12mm socket and ratchet to remove the two bolts, each one securing either side of the tank.
GS500 Gas Tank Removal
5) Gently lift up on the rear of the tank and slip a piece of wood to support it.
GS500 Gas Tank Removal
6) From the right side of the bike looking towards the left, the fuel tap is visible under the tank.
GS500 Gas Tank Removal
Use the flat-bladed screwdriver to turn it to the off position which is horizontal.
GS500 Gas Tank Removal
7) Using the pliers, loosen the two hose clamps and remove the fuel hoses from the fuel tap. Make a note of which hose goes where. I used a zip tie to mark one side.
GS500 Gas Tank Removal
Have a rag handy to catch the couple drips of gas that will be in the hoses.
GS500 Gas Tank Removal

8) Remove the water drain hose
GS500 Gas Tank Removal
All three hoses removed:
GS500 Gas Tank Removal
Another shot of the three hoses.
GS500 Gas Tank Removal
9) Now that the tank is free of the hoses, lift up on the rear of the tank and pull towards the back of the bike slightly. The tank should come free easily. Place in a safe place.
GS500 Gas Tank Removal
10) Installation is the reverse of removal. I found it easiest to put the rear fuel hose on first, and then the front. They are quite close together and make for a tight fit.
GS500 Gas Tank Removal
11) Remember to turn the fuel tap back to the on or vertical position.
12) There is no specified torque for the two rear 12mm bolts.

Other GS500 Guides/Howtos: