'84 1150 rebuild

[wyly]

yeah but that one was used Ray...has it been dropped? has it been used as a hammer, has it ever been re-calibrated?
and it's a click system. I have tinnitus so hearing a very quiet click is difficult.

The new wrench I new is about $150, it's got LEDs that change color as I approach the torque level I program into it, another when I reach it and another if I go past.

[wyly]

I'm stumped, I've consulted the Haynes manual and the Factory manual and neither show how the choke cable is to be installed. It must be considered too obvious to mention, very frustrating to brought to a standstill by a simple choke cable.

I never disconnected it at the bar and the carb connection seems straight forward but I have about 3 inches of unsheathed cable, so it's totally ineffective if the ends of the sheath can't seat into anything, that curved tube is on the carb but it ends well short of that even when adjusted to the max.

I got this bike is a rebuild project and it hasn't run in 25 years it is possible the incorrect choke cable was added later by the PO and is too long. The PO couldn't have operated as it is unless he pulled on the choke rod.

I looked at parts schematic and my cable looks different than the schematic but online schematics are often blurry and hard to make out.

[londonboards]

Oh dear - that really told me.

He he was talking about cam cover bolts. NOT cam cap bolts. Yes of course cam cap bolts need to be torqued to spec. But the cam cover bolts need very little. Finger tight and a quarter to half extra turn works just great. I've never had a leak.

With your experience Ray, it staggers me that you haven't got the "feel" of those cover bolts after all these years.

Much better to use "feel" than to encourage someone to use a cheap wrench that will inevitably end up with another
stripped cam cap.

You are the guru - but you can sure be vitriolic. Puts one off a bit.

[GS1150Pilot]

Snap-On isn't cheap. They are among the very best. I use Snap-On torque wrenches and you can feel the click as much as hear it.

[londonboards]

OK it's difficult to know where you are with this without a pic.

The choke cable comes through the curved tube attached to the carb tops. The cable should have about 3 inches protruding from that tube with the handlebar choke lever in the fully off position. It then connects to the choke mechanism on the no.4 carb. If you have assembled the carbs correctly all should be good. I once assembled a set of carbs with the choke clip on carb no.3 and thought I had an incorrect cable.

[wyly]

ahhh! fantastic you've given me the clue I needed I see the problem!
I reassembled the carb as I found it as I was assumed it was running 25 years ago. I see the choke attachment is in the wrong position. I'll have that corrected in about an hour.

Many thanks Richard

[londonboards]

Well done. Keep going.

[wyly]

okay, carbs primed, choke corrected, fuel tank connected, fresh fuel, turn key instruments light up, kill switch good, in neutral and ...nothing, silence hmmmm.

is there a secret Suzuki starting method?

the side stand warning light is on even though the stand is up, can that prevent starting?

my factory troubleshooting guide doesn't even cover total silence as a symtom

possibly the battery is too low I'll put a charger on it, I would think if turns on the lights it should at least have enough charge to turn over the starter once...

[wyly]

PULL IN THE CLUTCH!!!!!!!....yes after 25 years the GS lives!!!!!


I haven't done a proper synch on the carbs but she revs beautifully.....

[londonboards]

Well done. I know what a joy that is after all the work you have put it.

Job well done.

We just want pics and videos now please!

Here's one I did earlier:

[steve murdoch]

PULL IN THE CLUTCH!!!!!!!....yes after 25 years the GS lives!!!!!


I haven't done a proper synch on the carbs but she revs beautifully.....

Making a racket again for the first time in 25 years is outstanding.
As Richard mentioned, video evidence is now required.

[wyly]

Making a racket again for the first time in 25 years is outstanding.
As Richard mentioned, video evidence is now required.

another thing to learn, how to upload a video. It took me forever to figure out how to post a photo....but I'll try.

[wyly]

if anyone has some ideas what might be wrong with my fuel gauge, it shows empty when I have a gallon in the tank?

and with my the stand stand warning light, it's shows down when it's up.

I can live with the side stand malfunction but the fuel gauge would be nice to have operational.

electrical issues are always my biggest mysteries.

[dorkburger]

That may just be reserve. With the valve "on", mine runs out of gas as soon as the needle hits E. Then a switch to reserve. Im pretty certain that reserve is somewhere around a gallon.

Oh, and congrats on getting it running.

[dorkburger]

Factory manual states 5.2 quarts reserve (4.9L) you may be fine...

As far as the side stand switch goes, did you try to push up the switch by hand in case that its not pushing up far enough? I think holes are adjustable.... I had a bad switch on mine.