GT550 budget build

[Cragdog]

I found this one. Anybody see any issues with trying to wire it like this?



Any electrical gurus out there know why the starter relay is a dotted line?
Thanks!

[Suzukidave]

If you run a jumper wire from the + side of the battery to the red going to the coils you bypass everything , soon as you make the jump you are hot and the engine should run ( if it will ) to stop the engine you would have to disconnect the + from the battery. http://www.suzukidave.com/index.php?cmd ... hmZDM3OTJl" onclick="window.open(this.href);return false;

[Alan H]

The dotted wire going from the starter solenoid to the battery should actually go from starter switch relay (solenoid) to earth. The starter will work if the ignition is on and the kill switch is on. The engine will stop when ignition or kill is off.
As it is in the diagram, the starter won't work as the path for the solenoid circuit is via the coils and points.

It may be dotted because someone was farting about and didn't know what they were doing. It's certainly wrong.

[Cragdog]

Thanks Dave and Allen, I am going to try the jumper route later tonight and see what, if any, luck I have..

[Cragdog]

So I didn't get to working on the GT last night... I was putting the wiring back together and wham-o! Roommate comes running out of the house: "There's water pouring from the ceiling!" Turns out our neighbors upstairs were snaking a clogged pipe and broke something, now the ceiling in my bathroom is sagging and falling apart and there's water all over the place... Wonderful start to my evening. Anyway, so I put everything away and had to deal with that for the rest of the night. I'm hoping that tonight I will actually be able to make some kind of progress on the bike, but being as broke as I am and Christmas coming up I'm pretty stretched thin and can't be spending $$$ on parts for a while.
Just for my own sake to remember what needs to get done I'll make a little list:

Carb dust boots (try homemade method that Nate did)
Carb choke (missing screw, wont stay in choked position)
Figure out why carbs are pissing fuel from overflows ( no vacuum??)

Time points breakers (have a timing light, need to learn how to use it..)
Gap points properly
Sync carbs

Determine wiring problems (possibly rebuild harness)
No light at Headlamp (have 2 bulbs, neither worked)
Rebuild right hand controls (missing pieces)
Test voltage regulator, rectifier, and alternator (kokusan)


Later down the road:
New tires
Chain
Rebuild brakes (front and rear)
Inspect forks
Run a tap on right cylinder exhaust stud
Clutch lever and cable
Rebuild swingarm and address rust
New seat
New handlebars
lower gauges and headlight
Expansion chambers
... Burnout down the road

[Alan H]

Easy peasy!!!

[Coyote]

Carb choke (missing screw, wont stay in choked position)

Do you have the ball and spring? There is a shallow detente in the choke lever. The spring loaded ball is what holds the choke lever in place. What 'screw' are you missing?
There are several small pieces in the choke lever assembly. A shouldered large head main screw, a short nylon spacer sleeve, a washer and a lock washer. Plus the spring and ball. I think I have a spare spring and ball if yours are missing. A spare lever as well. Sadly, none of those choke pieces are available, so you may have to improvise on some missing things.

[Cragdog]

Carb choke (missing screw, wont stay in choked position)

Do you have the ball and spring? There is a shallow detente in the choke lever. The spring loaded ball is what holds the choke lever in place. What 'screw' are you missing?
There are several small pieces in the choke lever assembly. A shouldered large head main screw, a short nylon spacer sleeve, a washer and a lock washer. Plus the spring and ball. I think I have a spare spring and ball if yours are missing. A spare lever as well. Sadly, none of those choke pieces are available, so you may have to improvise on some missing things.

Mine has the choke lever, but no way to keep it in the "start" position, I guess because I am missing some pieces for the lever position. Here is a picture of what it looks like so you can see what is missing. This is my first experience with these bikes so I'm sure what all is missing.

[pearljam724]

Any screw or allan head bolt of that metric size will work. Just be sure to add a flat and lock washer. The lock washer allows you to slightly adjust the torque time to time. Allowing the chock to open, close. Stay open or closed. Or to partially close the choke as the bike warms. Depending on how tight you torque that screw. If it's too tight or loose. You won't have the flexibility to do that.

[Suzukidave]

Page #29 gives ya a picture http://www.oldjapanesebikes.com/mraxl_G ... cover.html" onclick="window.open(this.href);return false;

[Cragdog]

Thanks guys, I might need to tap that hole however, I tried putting another bolt in there and it didn't go, I think the original one broke off and is stuck halfway inside. Probablble need to drill it out and run slightly larger threads with new bolt and washer.

[pearljam724]

Here's a picture of the original bolt/screw, bud. You could copy that picture, then zoom in on it to get a better idea of what it looks like. If it were me, I'd just buy a stainless allen bolt of that size.

[pearljam724]

Does anyone have a good idea where I can buy grommets of nearly the same size diameter and thickness that are installed in the Ram Air scoop pictured above ? I would like to replace them with black ones. The white ones are starting to look shabby. Perhaps, I could soak them in bleach and see how they turn out. I looked at a few local hardware stores hoping to get lucky and found nothing. Any other grommet on these bikes or any other that come close that someone may be familiar with ?

[Coyote]

Nrw grommets are still available;e from Suzuki, however they are pricey at around $3 per piece. And they are still white. I think finding black ones is a real shot in the dark due to the wide slot that locks them in the hole. Bleach them is your best shot. I did improve the appearance of mine by using new stainless washers and stainless button head allen screws. Sure looks better than the OEM magcheesium screws. Maybe some larger washers would cover the ugly white. Some tedious work with a Sharpie maybe?

[markush]

Does anyone have a good idea where I can buy grommets of nearly the same size diameter and thickness that are installed in the Ram Air

Look for "cable bushing" at your local electronic-parts-dealer