Lost all power?

[Guest]

Hello, I picked up a '77 GS550 about a month ago, replaced a ignition coil, new o-rings in the intake & carbs, cleaned up some butchered wiring, etc.

As I was adjusting the mirrors, I broke off the Lights on/off switch on the left control, leaving me without lights. I ordered what I thought was the right one from Ebay, it wasn't. The connector was the same, wire color the same, but it was slightly different and the wiring internally was different. I plugged it in, and still had no controls. I tried the old one again and now the old one didn't have turn signals, horn, etc. and NOW wouldn't crank with the starter button. I still have spark with the kick starter, and the only fuse I found was a glass fuse attached to a red wire from the starter solenoid.

Does anyone know of any other fuses or ideas I could check? Thanks!

[cowboyup3371]

Those glass fuses can look good but still be busted. Check it with a multimeter or test light to ensure current is flowing

[ProfessorMoto]

Is this the only fuse that is on this bike? I replaced it with 3 fuses with continuity.

[cowboyup3371]

Do you have a service manual and wiring diagram for your bike yet? If not, go here and download it - http://members.dslextreme.com/users/bikecliff

You can also review what's on your bike using the parts fiche at any of the Suzuki motorcycle dealers; one such place I use is http://www.partsoutlaw.com/oemparts/...59d/electrical

Your bike should have two fuse blocks on the right side of the air box; one is for accessories while the other has the main fuses. Can you take a picture of that area if you cannot find it?

[ProfessorMoto]

This is the only fuse I've found.

[cowboyup3371]

What is (in) that white box next to the solenoid?

[cowboyup3371]

So I went back to read the service manual (have you downloaded it yet?) and found that the '77 does indeed have only one fuse (look on page 159 of the book or 165 for Adobe's writing). It looks like the parts fiche on the site I posted above has both the N and C in it with the C being your set up.

[ProfessorMoto]

That is the rectifier.

I have continuity throughout the starter button and switch, they both get voltage. The starter button will turn the bike over for one revolution and stop, I have to wait a minute or so, and it'll do the same thing again.

Yes, I did download it, thank you for the link.

[ProfessorMoto]

Update; after checking all the connections I decided to play dummy and check all the grounds. I took the rectifier off as it is also grounded through the airbox to the frame WHICH was disconnected to pull the carbs!

Never thought of the air box being part of the ground!

Thanks for the hint about the silver box, Cowboy

[cowboyup3371]

Great news, glad you figured it out.