How to change the throttle on a 1980 GS550?

[zincoxide]

Hello,

Bought my first ever bike, a GS550, 1980 which has been chopped and turned into a hardtail - and it's sweet!!\\/

But thr throttle cable has snapped and I need to replace it, I've got the new cable (stock cables still fit it) and just wondering if anyone has a clear guide of how to change the throttle cable easily and without causing myself any problems?!

I've tried searching the forums but can't find anything, any help would be much appreciated!

Cheers

[8trackmind]

Changing the cable is easy...after you pull the carbs off.

[zincoxide]

Grr!! I thought it wouldn't be as easy as just changing a cable!!

So, how to I get the carbs off and what do I need to be careful of?

Planning on doing it this weekend so have a couple of days to prepare!

[Tom MLC]

:???: Ya gotta pull the carbs to replace the throttle cable? Geez, I'm glad I don't own a 550. Might be easier to trade up for an 1100!

[QuaiChangKane]

:???: Ya gotta pull the carbs to replace the throttle cable? Geez, I'm glad I don't own a 550. Might be easier to trade up for an 1100!

No doubt!!!


I've been able to change throttle cables on all carbed bikes I've owned without removing the carbs. Your should be the same way, unless it's an 80's 2-carb set up - in that case, I plea ignorance...


On my 750, if you remove the tank, you can see the throttle linkage. You have to rotate it up by hand and play with it to get the ball on the new cable to seat, but after that it's smooth sailing. I've also used a screwdriver and tie-wraps to hold the throttle linkage up while installing the cable.

Just make sure to install the carb end first, then the trottle sleeve end. It sucks, but it's doable. Also make sure you fully loosen the throttle adjusting nut at your carbs - it can give you an extra 1/4" - 1/2" of slack while trying to seat the new cable at the throttle sleeve.



(Not as hard as seating your carbs into new boots, though!!!)



-Q!

[ddaum]

Q is right. You shouldn't have to pull the carbs. I've done it on my 1980 GS550 just the way he explained. I actually found the hardest part was correctly routing the cable inside the throttle housing on the handle bar, then juggling the two screws into place while trying to hold the darn thing together. It helps to have a helper....

[8trackmind]

:???: Ya gotta pull the carbs to replace the throttle cable?

After you do it the first time, it's easy. 10 mins tops. There is another way though.

It sucks, but it's doable. Also make sure you fully loosen the throttle adjusting nut at your carbs - it can give you an extra 1/4" - 1/2" of slack while trying to seat the new cable at the throttle sleeve.

Do what he said but...Loosen the clamps on the engine side carb boots. (not the airbox boots) Take the bolts holding the air box out. You should be able to slide the carbs (and airbox) back about an 1/2 an inch. The carbs will still be lined up since you're not really taking them all the way out.

[Tom MLC]

:???: Ya gotta pull the carbs to replace the throttle cable? Geez, I'm glad I don't own a 550. Might be easier to trade up for an 1100!

Okay, I was being facetious. But I have never had to remove the carb rack to replace the throttle cable, on any of my scooters. 8track, you might enjoy the sport of carb R&R.:roll: I think I'd rather have a toenail removed!:shock:

[8trackmind]

Okay, I was being facetious. But I have never had to remove the carb rack to replace the throttle cable, on any of my scooters. 8track, you might enjoy the sport of carb R&R.:roll: I think I'd rather have a toenail removed!:shock:

No, I don't enjoy it. Carb wise, everything is right there in easy reach on my 1000. The 550 with those big cv carbs is a bit more of a challenge. Clutch cable on my 550 isn't as easy to change as a 1000 either. Everything else is pretty much in the same place as any other GS though.

[8trackmind]

QI've done it on my 1980 GS550 just the way he explained.

Good on ya, Dean. I gave up after an hour and slid the carbs back.

[zincoxide]

It took me 20 minutes!!

My bike is a 550 but it's been chopped and turned into a hardtail, pics to come soon. Anyways, I simply lossened off the carbs, moved them back about a 1/2 inch and managed to change that end of the throttle cable, then I ran it up to the bars and that took seconds to fit!

All in all, about 20 mins to do, just need to run the bike til it's warm then adjust the cable to make sure I'm not running over idle.

All it needs now is indicators, the speedo wiring & a new set of mirrors. Then a simple spray to make it look better.

By chance, does anyone know what size the bolts are on the frame to the wheels? Want to order new stainless steel ones!

[txironhead]

Hope you get the pics soon, I'm a sucker for metric choppers.

Ya know, I understand the desire for a "clean" look, but every time I see a bike that's had the blinkers and mirrors removed I wonder how clean it's going to look when a pickup runs over it because the driver couldn't see the bike and the rider couldn't see it coming up behind him......

Glad to see you're rectifying the problem!

[zincoxide]

By chance, does anyone know what size the bolts are on the frame to the wheels? Want to order new stainless steel ones!

Just been thinking of this - does anyone know if I can buy a new complete set of stainless steel bolts from anywhere?

And where are the best places to get:
1. White Wall Tires
2. A new front mudguard made (was thinking a blacksmith?
3. Dampers to fit between the seat & hardtail (just small spring dampers to take the shock out of any bumps)

Cheers!!

Oh, and pics within the next week, it's a promise. As long as you remember she's looking a little worse for wear until I get her done properly!

[txironhead]

If you keep an eye on this guy's auctions, he usually has a set of stainless allen bolts for the engine, or you can email him and ask for one:

http://cgi.ebay.com/ebaymotors/Suzuki-GS750-GS-750-Restoration-Stainless-Bolt-Kit_W0QQitemZ300037234632QQihZ020QQcategoryZ10066QQrdZ1QQcmdZViewItem

For the seat springs, I'd check out Cycle Re-Cycle online. They've got a lot of "chopper" parts like solo seats, universal headlights, etc.

As far as a mudguard, do you mean like a front fender, or something behind/below the fender? If you want a custom fender, there are several places online selling fender "blanks" that can be drilled and cut to what you want. I've even fit chrome front fenders from other bikes with only the occasional need to elongate the holes.