Motorcycle Repair: suzuki electrical problem, suzuki gs500e, faulty component

Question
Hey Chris! I have a suzuki gs500e. After having it stand outside in the winter, it was dead even though I had put in a new battery. I checked the 20a fuse that went into a round thing on the right hand side of the battery and it was out so I replaced it.  I jumped the battery and started it from a car battery and the lights and horn worked. the bike started with some coaxing but then when I had let it run in neutral about 5 minutes I tried to put it into gear and as I clicked down it cut out.  The battery is new for two months or so.  When I try to turn it over without the car battery there is no sound and no turnover, no headlight  and a very faint oil light. could you please provide me with some trouble shooting tests so that I can check to find the faulty component here?  the bike does start from an outisde battery just dies immediately when put into gear. pulling in the clutch deosn't affect it. just kicking into gear.  ideas?  

Answer
Hi Heather.
 Well you did a few major things wrong and here's your chance to learn from them, allbeit the hard way.

1)  You let it stay outside over the winter.  Next time, find a shed, porch, barn or anything to give some protection to the bike from the harsh winter elements.

2)  You let the battery go flat.  So that cost you a new battery.

3)  You didn't say it, but I figure that you left fuel in the bike as well.  That means that the entire fuel system is contaminated with what we call "varnish".  It's residue left behind when fuel begins to evaporate and it gums up the carbs.  Next time drain all of the fuel from the bike and burn up any left in the floats by running the bike till it dies (after you have drained the tank).

Here's what you will need to do and put aside a weekend to do it (or your evenings after work for the week);

1)  Pull and clean the carbs thoroughly.  Pull and reseal the tank.  This is about 24 hours total time (mostly waiting on the sealant to dry)  Use the wait time to work on the carbs and the other thing on your todo list.

2)  Using the references in the manual, check the wiring for shorts and corroded connections.  Clean all of the contacts that you possibly can.  1000 grit sandpaper is good for that, just sand till the contact is a bit shiney.

3)  Don't just look at the fuses, test them with a multimeter to see if they are really good.  Replace any that are not.  Check and clean the fuse connections as well.

4)  The side stand cutoff switch is bad.  Either replace it or bypass it.  That is the reason that your bike cuts out when you put it in gear.  BTW; this is an extremely common problem amongst japanese bikes.

Do those things and let me know what happens.
Good luck.
FALCON