1984 GS550ES / can't figure out electical issue

[Neebs]

I?ll have time to work on it some more this weekend, will get some good pictures to post then. In the meantime, can anyone think of a reason why the handlebar start button would send such a high resistance signal to the starter relay connection?

 

[Neebs]

I finally had time this weekend to work on the bike some more, and finally found the culprit. I thought I had located all the grounds on the bike, but realized there was one more after I looked at the wiring diagram. It took a while, but I found a ground wire that had been completed severed and stuffed in with a bunch of other wires. I?m not sure what the original owner was thinking when he did that. But once I got that wire properly attached, the bike has a nice strong crank, and every other electrical anomaly has vanished. Since things were looking good, I hooked up a fuel cell to the carbs and tried to start the bike. For a brief moment it sounded like it wanted to start, but then just kept cranking like normal. I noticed that the fuel from the cell was pouring out of both carbs. So I?m guessing a carb rebuild is my next step, although I can?t figure out how to get this airbox out of the way. I removed the battery and battery tray and it?s still not enough space. Does anyone know if there is a trick to removing it? Any dos and don?ts for carb rebuilding would be helpful too, never tried it before.

 

[tom203]

Yep...time for carb fun....no shortcuts or you'll be repeating the fun.

"I noticed that the fuel from the cell was pouring out of both carbs. So I?m guessing a carb rebuild is my next step, although I can?t figure out how to get this airbox out"

Probably similar to other 550/650...you likely need to loosen rear fender and push it back to get a little space to slide other stuff and airbox/airfilter back. One half inch is a big deal here. Then you can remove carbs...take pics to remind yourself where stuff goes.

 

[Neebs]

Is there any downside to using pod filters? I?m about to break this airbox just to get it out.

 

[tom203]

Is there any downside to using pod filters? I?m about to break this airbox just to get it out.

Downside ?,,,,how much carb fun are you hungry for? Stock filter setup is easiest to get right - once you have clean carbs. Honest, you don't need to remove airbox, just push it back and get carbs out.

 

[Gorminrider]

Tom is right. don't take it out, undo the rear fender etc....applying warmth to the rubber parts will soften it will aid removal and replacement of carbs..a "heat gun" or a hot rag will help. Don't overdo it and don't run the heat gun around gasoline fumes.

Get the bike running properly with the stock setup first. Learn to orbit the earth before landing on the moon.

 

[Cipher]

so was the ground the wire that connects on the left side small gauge black white stripe?

 

[fbody_mike]

This air box will actually go far back and give plenty of room. Just remove the battery, the Igniter and unclip the fuse box, then remove the battery box. Now just remove the two bolts on top of the air box and the crankcase breather hose and it will slide back 2 to 3 inches. Remove carbs to the right of the bike.

 

[Steve]

Any dos and don’ts for carb rebuilding would be helpful too, never tried it before.

Rebuilding the carbs is not all that hard, but does require a few special tools and some chemicals.

If you don't feel comfortable with the idea of doing them yourself, there are a few of us that do offer that service for a modest fee. I have done two sets of carbs like yours with good success.

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