My GT550 Project

[SW550]

Parts are ordered and some are already here for my '74 GT550.
I have found to be careful w/Ebay and the high prices you find there. Of course I have done business on Ebay for many other items so I already knew that what looks like a good deal just may not be.
I want to retro my GT back to the original look and some items I need are hard to come by like a decent full set of exhaust pipes.
I have found that Bikebandit and Motosports.com is a good source for the GT's, not so very much though for the 72/73 yr models.
I picked up new stock airfilters, exhaust baffles from Motosport, the exhaust muffler header gaskets and the exhaust couple seals from Bikebandit at way low prices than anything I found listed on Ebay.
Also, just because Motosport doesn't have the part you are needing be sure to check Bikebandit, as I have found most of the parts I needed at one or the other and if Motosport has it, Motosport prices will be lower.
Bikebandit does ship faster than Motosport but for me that is not a issue.
I have also done business with Paul Miller, he too though seems to have his prices high but I have found a few decent priced items with him.
I search all over for frt turn signals and the ones I saw on Ebay and the high prices were crazy considering the condition they looked to be in. I instead ordered a front set through Z1Parts.net, they don't have much for the Suzuki's but they did have brand new 72-76' turnsignals.
I had my handlebar switches retro with Brown-WOW, super job.
Once I really start tackling the GT I'll be checking back in I'm sure with questions, the one issue I know I have is the Electric Starter doesn't work. If it is the Starter, is the Starter accessible w/o taking the motor out of the frame? There is nothing when the starter button is pushed ( no noises). Kick starter works perfect, this 550 will start on the 2nd kick.
http://www.bikebandit.com/1974-suzuki-g ... #sch276647" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;
http://www.motosport.com/motorcycle/oem ... -%28GT550L" onclick="window.open(this.href);return false;

[yeadon_m]

Yes, the starter can be removed simply by dropping the gearbox oil, removing the centre pipes and the starter cover. Two bolts and the lead off, out it comes.
Good luck! Mike

[Alan H]

If the starter motor doesn't turn check the wiring to the solenoid and motor and make sure the starter button works the solenoid first. , no clicky, no worky.
Starter motors are usually very reliable.
Early starter clutches less so, you can either upgrade to the later type or replace springs, plungers and rollers if the running shaft is OK.

If you do a search for GT550 starter clutches, you'll find lots of info.

[Coyote]

There is nothing when the starter button is pushed ( no noises).

Had the same issue. Turned out to be the starter motor brushes worn out of tolerance and one of the 2 cracked. Depending on the brand (Kokusan / Denso), brushes may or may not be available.
All is not lost though. Another member here (Lane) made his own NLA brushes. Bought some oversize brushes at the hardware store and filed them to fit. Carbon is soft and easy to shape.

[Suzukidave]

I got a set of new brushes at ( of all places ) a vacuum repair business , they had a cabinet with drawers of all different types .

[GT750Battleship]

Hi,had the same problem on my GT750.....it was the starter motor brushes,Suzuki has discontinued the positive brush.....I made mine work by adapting another negative! now starts first time every time,still like to kick start it when it's warm.....exercise,in my old age !!
Cheers,
Roger.

[arneg]

hey you can have my set of original pipes. they came off a few weeks ago for Jemcos. They are in very good condition, not rusted, no dents, etc. message if interested.

[Suzukidave]

hey you can have my set of original pipes. they came off a few weeks ago for Jemcos. They are in very good condition, not rusted, no dents, etc. message if interested.

Hey thats so cool 25 posts in and your already one of the group

[SW550]

hey you can have my set of original pipes. they came off a few weeks ago for Jemcos. They are in very good condition, not rusted, no dents, etc. message if interested.

P.M. Sent

[SW550]

Thanks for all of the responses to the Starter issue , once I get that far, I'll let you know what the problem was.

[SW550]

My Suzuki Service Repair Manuel had nothing in there about removing the starter, it only mentioned it when the Motor was out of the Frame.
Once I get to the starter issue I'll check all of the wiring as I noticed the front brake didn't activate the brake light either and being the front turn signals were removed, I noticed other loose wires were disconnected inside the headlight housing.

[Coyote]

Starter motor is easily removed with the engine in the frame. If your exhaust pipes are on, remove them. Now the work is flat on your back. The starter motor cover is held on by 4 bolts. Remove the cover and set it aside. The starter motor is secured with only 2 bolts. Remove those bolts and slide the motor away from the crankcase (horizontally). It may be snug as there is an o-ring on the snout that fits in the motor. The starter motor will fall right out. You can bench test the starter motor with a battery or a battery charger. Hook the neg lead to the starter motor case and touch the pos to the lug where the cable mounts. The starter should spin with plenty of torque. Put your foot on top to keep it in place while testing. If the motor does not spin, the most likely cause is worn out brushes. Unfortunately, the brushes are not externally replaceable. They are inside the motor. The motor is easy to take apart, but kind of a bear to put back together. Installation is the reverse order.
A word to the wise. Drain the transmission before removing the starter motor, unless you enjoy a face full of oil.

[SW550]

A word to the wise. Drain the transmission before removing the starter motor, unless you enjoy a face full of oil.

I'll be sure to remember that.

[Cragdog]

I had my handlebar switches retro with Brown-WOW, super job.

What exactly do you mean by this? Got any pictures of the bike?
Keep pluggin along!

[SW550]

I had my handlebar switches retro with Brown-WOW, super job.

What exactly do you mean by this? Got any pictures of the bike?
Keep pluggin along!

After I sent these across the Pond, I did see a new right side switch assy on Ebay but the Work that Brown did is amazing.
The turn-around time was impressive as well. Browns retro included not only new paint/smooth moving switches but new wiring too.