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GS 550 electrical issue now? Ignitor? Voltage Regulator

  • Thread starter Thread starter ajgs550
  • Start date Start date
A

ajgs550

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Ok. . . heres the deal.
1978 suzuki gs550
The previous owner said the bike was running so/so the 3 years prior, and sat for about 1 year before a purcahsed. When I bought it it turned over and that?s it ( I got a deal)
19,000 miles
Just finished fresh VM carb rebuild ( new o-rings, floats, jets, gaskets, the works)
Full rebuild on Head (valves, valve seals, re-shimmed) lash is .003-.004
I left the lash a little on the top side of the lash for a little wear in
honed the jugs, and re-ringed all 4

The engine cranks right up with no problem, and the bike idles pretty darn good without carb fine tuning, but the first time I went down the street and went to go past 5,000rpm the darn thing hits a wall and loses power big time! Seams almost fuel related but its getting gas to all four and the plugs show it. Now I have been reading as many threads as I could and a common tone is the ingnitor? What the . . ? I can?t even find it on the wiring diagram, what else it would be called? Is this the same as the voltage regulator? I checked the battery and it has 11.9 volts not running and about 13.4 volts at 3,000rpms. I have not ohmed the coils or any other component. My timing is pretty spot on, and the timing light shows my mechanical advance working. Can you test the ignitor or voltage regulator? I posted a pic of what Suzuki calls the voltage regulator (silver thing - Suzuki part#32500-45011) Any wisdom out there?

http://www.youtube.com/watch?v=VIlDDDxkuG8
 
Unless you have an aftermarket ignition you don't have an ignitor. Check under the right hand cover on the end of the crank and see if you have points. You could have wither maladjusted or burnt points, bad condensors, timing set wrong, float level set wrong, or jetting needs tweaking.
 
What you describe sounds like a lean mixture problem. Just in case you didn't know, any changes to the intake or exhaust will require rejetting.
 
AJ,

To further state what has been stated above:
- A 78 will originally have had contact points and capactors (not electronic pickups) and of course coils and no ignitor module.
- Maybe sometime in its history someone has replaceed all that with electronic ignition. BUt you probably would have noticed that.
- start by looking to see if still has points.

May or may not be related to topic you discussed, but looking at your photo: You will want to check you battery electrolite level. Use distilled water. In the photo the 3 cells on right side look low, out of sight.

The ignition system and the charging system are some of the things things that was redesigned on most model for the 1980 models (carbs too, and lost kick starter). Keep that in mind if someone is telling you something that doesnt make sence, perhaps verify if they are speaking specifiacally about pre 1980.

And I have only had 1980 & 82 models. So I cant tell you about the sort of regulator you have. But, in general a good test of any regulator is just a good test of the entire system, and then know that every part of system is okay. WHich you have done. Your voltage could be a little higher, but your test shows the charging system is working, at least nothing completley failed.

But lets not loose track of the original question: Not reving over 5000, and if that would be related to ignition, or other.

Tell us if original stock exhaust, air filter, air box.
What can you say about condition of carb boots and intake boots and o-rings.....

Thanks for posting the vidio. Exhaust does not look stock.

.
 
Last edited:
Ok . . that makes sense. I do have points, and I replaced both the condensers, and points. Also I replaced the o-rings on the intake boots, and all look to be in good shape, and were no too hard.

right now I have the stock header pipes, but took off the mufflers because they were shot, so I could be loosing some back pressure there. I also ditched the stock air box and put on Emog pods. I have a MAC 4-1 coming in the mail so jetting is obviously in the future, but I still thought I would be able to get her to run, just may have been leaned way out).

I'll check the battery level, and then progress to checking the charging system. I did notice that when I increased RPM closer to the 5,000ish RPM wall the voltage had dropped to about 12.8 volts.

I will also pull the carbs, re-check float level, and also check fuel connections (petcock, vacuum connection, fuel line . . . ect)

Thanks for the input all ... We'll see what the weekend brings!
 
"I also ditched the stock air box and put on Emog pods"

There's your answer. You will have to do major re-jetting on the carbs to get it to run right.
 
doctorgonzo said:
"I also ditched the stock air box and put on Emog pods"

There's your answer. You will have to do major re-jetting on the carbs to get it to run right.
Click to expand...

+1

That in combination with no muffler cans.

You are running HELLA lean.
 
Jets . . .

Jets . . .

Sounds good . . . I'll check the carbs to see what I have in for stock . . . does any one have any ideas of where to be at for jets for a '78 550 with pods and a MAC 4-1 pipe?

First off . . . where is the best place to get jet kits for these old buggers? not sure where to start, local suzy dealer? . . . online?
 
ajgs550 said:
Sounds good . . . I'll check the carbs to see what I have in for stock . . . does any one have any ideas of where to be at for jets for a '78 550 with pods and a MAC 4-1 pipe?

First off . . . where is the best place to get jet kits for these old buggers? not sure where to start, local suzy dealer? . . . online?
Click to expand...

Z1 enterprises (just google them, good people) sells mikuni jets.

IF they make a dynojet kit for that bike that's the way to go, comes with everything you need, and the proper jets for 4 into 1 only, as well as 4 into 1 and pods, $120 bucks or so.
 
Bigger Jets = RPM

Bigger Jets = RPM

What what do you know . . . I found a old set of 750 carbs that had #97.5 mains in it. Swapped out the stock (#80's) that I had and the old girl woke right up. Took it up and down the street a few dozen times (no seat, pegs, lights . . I know, I know) and pulled it in for a plug check. The plugs were white as snow! I didin't think those individual pods would make that much of a difference. I think the answer will be bumping them up one or two more steps on the mains, and chaging out my stock pilot jet (15) for a 16.

thanks for all the help!
 
ajgs550 said:
I'll check the battery level, and then progress to checking the charging system. I did notice that when I increased RPM closer to the 5,000ish RPM wall the voltage had dropped to about 12.8 volts.
Click to expand...

Don't run it too much before you fix the charging system, the voltage dropping with RPM is indicative of poor connections in and around the stator, regulator, and battery. If left uncorrected the regulator will fail, and the stator, expensive parts. Catch it now and all you need to do is go through Posplayer's revised stator papers, do the simple tests shown there and start cleaning/replacing connectors, no real expense. Once this is done the charging system is as reliable as any.

http://www.posplayr.100megsfree3.com/FH012AA_Charging/Stator_Papers_Phase A.pdf
 
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