need help resurrecting a dead 550T

[Anonymous]

I was given an 81 550T by my girlfriends father a short time ago and have started the resurrection process. Not an easy feat considering it has been sitting for 13 years. I am mechanically inclined, but not wiring inclined and thats where the problem lays. On the right side of the bike it appears that there are 2 fuse panels screwed onto the air cleaner box, but it looks like there should be 3, is this correct? One fuse panel has 1 fuse in it while the other has 4 or 5. Also, the main power wire for the the battery wraps around to the right side, and at the end has an O connection. There is a little wire coming off the O connection that goes somewhere, but where does the O connection connect to? To one of the fuse panels? There is also a negative wire coming from the starter I think. Where should its loose end be connected to? The fuse panel also? Any information anyone can provide to me would help me greatly in getting this GS up and running. Thanks a million guys!

Gavin

[jimcor]

OK. What you're describing sounds to me like the bike is missing the starter solenoid. That is where the heavy, red, positive, battery connection and the lead to the electric starter should go. The starter wire is black, it is not a negative wire, also a heavy gauge it goes into the engine under that pressed steel panel. The solenoid is mounted in your 'third fuse box location' This is also where two smaller gauge wires would connect, one a ground and the other a positive lead from your starter disconnect switch. I'm not sure what color that wire would be.

You can get the solenoid at a Suzuki dealer or rig one up using a lawn and garden tractor part, about 15 bucks USD, which you should be able to get easier...and lots cheaper. If you can't find one of those use an old Ford type solenoid, but it will have some mounting challenges.

The fuse box with the single fuse is just a convenience accessory power outlet.

The other fuse box, with the 4 fuses, is the bikes main and only box.

You really need to spend a few bucks and get a Clymer or a Haynes manual for your bike.

[Anonymous]

Thanks for the info, I think Ill run down to my local Suzuki dealer and pick up a solenoid. So much for my hopes of getting her started this weekend. Im also trying to flush my gas tank, I was told use paint thinner and BB's and shake the hell out of it for awhile. Is this a good method or should I be concerned about the lead in the BB's? Is paint thinner the best to use or would something else work better? Remember this biek has been sitting for 13 years so its really dirty. Thanks for any info on this.

[jimcor]

You'll pay about a hundred Canadian, for a genuine Suzuki part! Get the same thing cheaper at the Canadian equivalent of Home Depot.


EDIT!!! Whoa! I almost forgot. There is a gas gauge sending unit in the tank. Hold off till you do a search on rust removal! Many threads on this subject. You might have to pull the float/sending unit before you do this


BTW real BB gun BBs are plated steel. Don't use lead shot!!!


If your gas tank is rusted your carbs will need to be cleaned too. Many, many, many threads on this. Search! 8)


Spend another 8 or 9 bucks for a spray can of electronic contact cleaner and clean all your bullet plugs and connectors and multi contact plugs. Takes a long time but you'll save time and money down the road.

[Anonymous]

The only thing connected to my tank is the petcock, so Im not sure if there is any sending unit in there. I already had to unseize the petcock. Plus there is already solvent in there How would I know what solenoid to buy? I dont even know what its supposed to look like. I should also probably find some bolts to replace the ones missing for the air cleaner box, its not held on by anything. Anything else I should check out before I try to crank her over? Already done an oil change. Thanks again guys.

Gavin

[jimcor]

If you don't have a gas gauge there is no float/sending unit. If you do there is!

Quick check of the wiring diagram shows the '81 T does not have a gas gauge. Good. Throw in some steel BBs a hand fil of old nuts and bolts and a handful of pea gravel. (all of which have been recommended to me over the years.)

OK, back to the solenoid. Call up anyplace that would sell outdoor lawn and garden equipment parts. Tell 'em you need a 12 volt solenoid for a Briggs and Stratton powered tractor. It's a generic type of part. Electrically one size fits all. In the states it'll cost you US $13. It will look like a an M80 firecracker glued to a Triscuit cracker. :roll: :roll: :roll:

If you want to get really cheap. Go to your local discount auto parts store and tell'em you need a solenoid for a '78 Ford Pickup with a V8. $8 US but it's the size of a 35mm film can glued to 3 Triscuit crackers. But it will not mount in your original panel and the connectors will have to be changed.

Can you tell I don't write tech manuals for a living. Trisciut crackers...firecrackers :roll: :roll:

[Anonymous]

Sweet, that helps alot. Uhhhh, how am I supposed to tell if I run out of gas? Hope I remember to leave the petcock on primary. Does anyone know of any good wiring diagrams for my bike, and where I would find them? The wiring on this bike has been messed around with.
Thanks

Gavin

[SqDancerLynn1]

Check out the smoke riders forum they have some 550 wiring diagrams

http://smokeriders.com/Technical/wiring_diagrams/wiring_diagrams.html

[Anonymous]

Thank you very much. Any books or magazines I should be aware of that would help?

Gavin

[Anonymous]

Wow, those wiring diagrams are about as easy to figure out as women....
Time to go buy that service manual, lol.

[skreemer]

I find that both my clymer's and hayne's manuals are invaluable...

if you get stuck and need help with something specific try a few PM's to the guys with 550Ts....

Firsttimer has one and that thing flies and looks good to boot.

[Nerobro]

My 550 WILL stomp that bike one of these days ;-) *grins* someday soon... BWAHAHAHAHAHA

[Anonymous]

I have a 1980 550L. The wire coming from the starter switch to my solenoid was green w/ a yellow stripe. I had to bypass and install a new switch on my side panel. Works Great now!