New GS Owner A few Quick Q's

[Kyoritsu]

First let me say how great it is to be part of such a well managed forum with what appears to be a full host of caring knowledgeable people, who can act like adults.
I've spent this last week reading through the forums and learning a lot. I found some of the things I was worried about to be nothing big, found some new things to worry about, and then after reading more found I was worried about the wrong things still.
I have a manual on order should be here in a couple of days.
PO wrecked all the little gen. maint. stuff: Chain tensioner, cables run wrong, fluids hi and low, etc. bike was left out unwinterized in New England, ran some stuff through the tank and the carbs seem to be running nice. Just need to adjust the idle. (stupid Pilot screws are stuck on all four VM Carbs, soaking them in PB since last night)

So down to the important stuff: 1980 GS550E, all the important stuff is stock. Bike has less than 20k on it.(course last owner did a few of those miles on the right side)
- Petcock vacuum has been bypassed and is on prime with a second shutoff in use and a screw in either end of the split tube. should I attempt to reattach properly then either rebuild or replace petcock as necessary or just leave it be? (whats the worst hat could happen?)
- I've managed to not have to remove the carbs to date but will certainly have to do it sooner or later, what's the best way to get the thing back on? Carb to airbox then to boots to engine?
- There's a hissing sound and in my opinion excessive heat from the top end, sounds like the cams and or chain may need more lube, should I open her up and take a look? do the cam bearings tend to ware out ever? could they be to tight? could they just need a little Lucas lovin? Maybe the tensioner just needs some attention?
- I read on here that the oil level should be checked while on level ground on the stand, then read on here that it should be done on level ground and on both tires (which seems ridiculous), which is right?
- are there any other common things I should worry about that may have been screwed up by PO i haven't though about?
- Just how important is it that he exhaust pipes seal well? is a little leakage ok?
- And lastly Does anybody have a suggestion as to which tools would be best for the on bike tool kit I'm putting together (hoping to use the original storage space but am willing to mod if need be)?

Thank Guys
Justin (Kyo)

[hikermikem]

Hi Justin - welcome to the forum. Bike Cliff will be along shorly to give you a proper welcome...

Here's my opinion on a few of your concerns:

- Get a new petcock (around $45 at Z1 Enterprises), rebuild kits are worthless. That way you'll never have to remember to take it off Prime. If it stays on Prime when not running there's a very good chance that fuel will make its way into the crankcase oil & that's not a good thing. Never run the engine if you suspect there's fuel in the oil. Unscrew the oil filler cap & take a good whiff, if it smells like gas change the oil..

- Getting the carbs off & on those 550's is a royal PITA. I think the procedure you outlined is correct - remove them from the left side. I also spray silicone around the intake/airbox boots openings to help the carb slip into them. Also, make sure you attach the choke & throttle cables to the carbs BEFORE you stuff them back in place - it's nearly impossible to do it afterwards.

- That hissing sound may just be that loose exhaust (if you're lucky). However, you mentioned that your cam chain tensioner was suspect... FIX THAT FIRST, a faulty cam chain tensioner can trash an engine.

- Remove the valve cover & have a look - adjust the valves while you are in there, it's probably WAY overdue anyways...

- Check the oil while the bike is on the centerstand on level ground (the rear tire will be off the ground).

- The exhaust should be leak-free for the bike to run correctly.

- Follow the carb clean-up tutorial here & do a proper carb clean - don't waste any money on rebuild kits - reuse all the old jets.


WE NEED PICS - good luck,

mike

[BassCliff]

Greetings and Salutations!!

Hi Mr. Kyoritsu,

You can also download a factory manual from my website. It should list the tools in the original took kit. That hissing sound might mean that your crankcase breather tube is plugged up. It might just be normal carb venting noise. It could be a leak in the intake system (intake boots and O-rings are usually mandatory replacements). Checking the oil either way, on the wheels or on the center stand, is close enough. Just make sure it's at least up to the "Full" level. Other things you should check are listed in the maintenance lists in your "mega-welcome". Let's get to it....


I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", the Carb Rebuild Series, and the Stator Papers. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[Kyoritsu]

Thanks for the warm welcome
The bike runs pretty well, I've done all the regular maintenance and got it road safe. The carb seems to be performing well and just needs to be tuned a bit for warm idle.
As far as the hissing sound, it's definitely from inside the top end and steady with rpm's, it sounds like a rusty chain would on an old bicycle or like old dry worn ball bearings would hiss. I figure it's got to be the chain rubbing on something or more likely the cam bearings aren't getting enough lube for some reason. Maybe some gunk blocked oil flow. I got very little nasty out of the engine when I flushed it. I live way out in the hill towns of Western Mass with lots of long lonely twisty mountain roads between me and the nearest towns and have already gotten a good 60+ miles on it. My main problem is money, so any thing that can wait will have to. like buying a head gasket, or petcock. plus most stuff will have to be ordered online anyway. for now I need to do some care full planning on where my money will go next. If the exhaust is leaking it's very slight. right now I'm trying to get enough money together for a new front tire, and then I've got my sights on a compression tool. I may end up having to buy some carbs after i kill these trying to get the damn pilots to budge.

[Kyoritsu]

Thanks for redirecting me to the greeting page, it was the first thing I saw when I signed up and I had just skimmed over it, but now that I've gone through it again, lets just say I'm glad I did. Didn't realize valves needed adjustment so often, this will be a yearly thing for me at the millage I intend to put on this bike.
I got the manual stapled to my desk top
Pics will be along shortly soon as I can look at it without a tool of some kind in my hand.
I've read up on most of what you suggested already except for the stator and I have only skimmed over the valve adjustment.
If I spend one more late night poring through these forums or under my new old GS my wife might do something drastic

As for the tools I was thinking new, more useful during a long drive, and hopefully already in my possession.

All my boots in and out are good for at least this year I do plan on replacing them soon though.

So I guess I'll be keeping 2-3 sets of top end gaskets on hand.

As for the petcock, whats the harm in having a gravity feed for the time being? Am I missing out on some performance or doing some kinda damage? There is a second fuel cut off installed that I turn off when ever I turn off the bike.

There are some extra ground wires here and there. I think the guy who had this before the PO must have run them and done the petcock thing too. Probably had the electrical issues right away and wanted to do some preventative stuff.

This is my first bike younger than me. My last and favorite being a 78 Honda hawk, it had a smaller engine, much less weight, and felt comfy. But this one has more even power through acceleration and handling I think I could get used to. And you can't beat the community. Plus this bike found me all by itself and spoke to my inner rebel, who in turn spoke to my outer rebel, who really isn't worth arguing with.

For now thanks for the warm welcome and quick attention.

I'm off to go burn and beat my carbs (why not put rubber plugs or some kinda cap over the pilot screws to keep 'em clean?)

[1_v8_merc]

If your having trouble removing your pilot jets, welcome to the club!

Anyways, below is a quick picture of a screwdriver(Kobalt) that is for sale at Lowes, and it fits perfectly right in the pilot jet cylinder and grips the pilot jets perfect.
It's in the cheap section near all the cheap screw drivers, and it's the Only One that looks like this.

(I have an 82 650g, so im NOT sure if the same screwdriver will fit your pilot jets as perfect as mine!) I had an extremely stubborn and stripped jet, I couldn't get it out for anything! I brought my carburetor right into lowes, and tried a buncha screwdrivers till I found one that fit!
I suggest you do the same, but I would still buy the screwdriver afterwards, since it only costed like $3 tops, lol.

Just like some of the guys on here told ME(which I didn't believe until it happened to me!)
But the screwdriver tip fitting in the jet is CRUCIAL, you can't just use a tiny driver that doesnt fit Snug into the Jet, you will strip it like I did.

Gotta find a driver that has a tip just wide enough as the jet slit, and i know that's a problem because 90% of american screwdrivers tend to be too wide above the Tip part of the driver!
(so technically you could just find an old driver laying around that has the perfect tip, and just take a dremel to the sides above the Tip, that way it clears the pilot jet cylinder area)

Hope that made sense!





-------------

Anyways, back to your other issues.

I would definitely replace the petcock(rebuild i guess?, or whatever the guys say to do on here)
Sorry never really had much trouble with mine....guess im like the 1 and a million lucky dude sort of.

As for your timing chain problem, I had the same problem I believe.
The noise coming from my engine was like a "scratching" noise.

But likely the problem is the Timing Chain Tensioner.
You can order a rebuild kit for it(actually you might have to get the parts separately)
OR, you can just "tighten" the tensioner, which is what I did.
I got very detailed directions vie e-mail from someone here, and it's very easy, I can send you the same thing if you want, just PM me or something.

Here's a clip of a loose timing chain....sadly on my bike, haha, but I got it fixed.

http://www.youtube.com/watch?v=n-CzItIGASQ

Watch it and see if it sounds somewhat the same, just to be sure.

[Steve]

Didn't realize valves needed adjustment so often, this will be a yearly thing for me at the millage I intend to put on this bike.

You don't plan on riding much, do you?

I realize I am more the exception than the rule, but even my wife puts on about 5-8,000 years on her bike.
Being "an exception" does not make me "exceptional", but I have logged 27,650 miles on my bike in the last 12 months.

Gotta find a driver that has a tip just wide enough as the jet slit, and i know that's a problem because 90% of american screwdrivers tend to be too wide above the Tip part of the driver!

What you are looking for is known in tool circles as a "cabinetmaker's screwdriver".
Characterized by a tip that is the same width as the shank.

.

[Kyoritsu]

That's my sound except worse

as for the screw driver, I dremeled a stubby down to just right, but the outside carbs just won't budge. Gonna have to take them off and do it right. Poor #1 may have to be drilled out.

As for my riding, I just don't have much free time these days, at best between work, 2 new kids and the short riding season 15-20,000 probably the most I could do. Chances are this year I won't put more than 3,500 on it. Just no choice right now.

When I lived down in FL I rode year round, had time for trips, and would frequently just disappear for a few days or more... ahh the good old days....

[RIP]

That's my sound except worse

as for the screw driver, I dremeled a stubby down to just right, but the outside carbs just won't budge. Gonna have to take them off and do it right. Poor #1 may have to be drilled out.

As for my riding, I just don't have much free time these days, at best between work, 2 new kids and the short riding season 15-20,000 probably the most I could do. Chances are this year I won't put more than 3,500 on it. Just no choice right now.

When I lived down in FL I rode year round, had time for trips, and would frequently just disappear for a few days or more... ahh the good old days....

I had the same problem with my #3, I used a 5/16 drill bit and ez out. I took the carbs off the bike, drilled the hole, sprayed withh PB Blaster, put heat to the side of the carb with a small torch, and extracted the jet with the ez out in a slow drill.

[Kyoritsu]

really starting to dig my new GS

Well, after many hours of cleaning, reading, undoing jerries, and then redoing stock or better
I've got
- The top end sound quieted some what after rebuilding the auto cam tensioner (it was locked, but now it's full of Lucas and shiny) still a little noise, I'll take a look at it when I finally get into the engine. Probably a cam chain guide worn a bit. Got me a cheap valve cover gasket and ordering a nice reusable 'Real Gasket'.
- Carbs I did a light rebuild (lots of love to our friend with the affordable rubber bits: Thanks Robert Barr:
http://cycleorings.com) and found the last bit of love it had seen was rough and dirty, they will need replacing as when I finished polishing the crap out of the throttle plates seat it turned out someone had already done an extra good job and the only reason they would seat properly was the crap between them and the barrel. The gas treatment knocked a ton of crap out of the Tank and filled the carbs with even more stuff for me to clean, but I found that leaving the carbs out in my co-opted workspace on the kitchen table over night with a towel over them not only helped bring the smell of motorbike into the house but also dried most of the crud into a nice manageable powdery stuff. Plus I truly enjoy watching my four year old see man things happen and being interested in what Daddy's doing. They are back on and idle is still weak but better.
- Treated the tank rust with 'Behrs concrete cleaner/etcher and rust remover' Formula 991, at your local Home Depot paint section. ($16 Sh*t worked great) got some flash rust cause I didn't move fast enough so stuck some magnets under the tank and around the clear fuel line leading to the in-line filter. Going to get a new tank with less dents next season.
- Did the forks to spec, came out a little tight but man does it stick to the ground, might do a progressive upgrade after I replace the rear hydraulics this winter.
- Next on my list is a valve job. Using my cheapy gasket to get in and out and hopefully will get my Real Gasket in time with what ever shims I might need to order.
- I ordered some relays and will be doing the coil mod as well as horn and headlight. Eventually I will get a nice big relay and centralize some of the electronics controls and leave some space for a nice custom "don't hit me set of led running lights" with a little "aren't I pretty" bit of led highlights for side visibility.
- Ran the recommended extra grounds (nice black inconspicuous solid 12 gauge) here and there and still seem to have power issues, when I hit the lights it almost kills my weak idle. Ordered direct to stock led tail and directionals in hopes it'll get through till I fix what ever is the cause.
- After that I want to replace the modded bucket headlight with an Led windshielded thing I found at a good price, this will hopefully leave me with a little extra power instead of hurting to push the halogen h4 that's sucking all my juice. Maybe even some fog style lights for these dark twisty mountain roads that never seem to fail in at least one surprise or another on any given ride.
- Any recommendations on a better than stock Stator? I'd like to add a horn that says more than "um.. excuse me please".
- Anybody now if it's possible to get swirls off stock exhausts? they are still in pretty good shape.

Tomorrow a little tank paint'n and some loud music (ELO for now though) speakers sound good pointed into the woods.

Thanks one more time, pics will be up soon with some befores and afters now that most the major stuff is done. (gotta get those swirls out and some rust and frame lovin.)