Project: 1985 GS550ES

the smog control stuff is only on the CALI bikes.

From your fuel tank there should be three hoses and two wires. the two wires are just the fuel level sensors/senders. The hose that comes out near them is a vent line. The other two hoses are fuel line and vaccum line.

My 550 has TWO smog cannisters located in the tail bodywork. Al Gore would be proud.
The fuel level sending unit should not leak but if it did it would be onto the top of the engine presenting quite the fire hazard so better safe than sorry.

Hi, I also have an 85 550 and had to get it running after 5 or so years sitting. It sounds like your low speed/idle jets are plugged with crud, mine were. Also the larger tube leading to the rear of the bike goes to the smog cannister which may be missing and the smaller one is a drain which will catch gas leaking from the fuel level sending unit and rout it away from the hot engine. Good luck

Yeah, it's almost certain that something is clogged in the carbs. Got the dip, now I've just gotta make the time to tear down the carbs themselves.

RE: Tubes (I believe you're answering my question from one of my first posts here regarding lines from the fuel tank, right?): The larger tube goes to a smog canister? We don't have those here in MD. That's a Cali only "feature", right?

The smaller tube catches gas from the fuel sending unit? Why does that leak?

Glad to hear that someone else got their 550 up and running. Hope you're enjoyin' it!

Since you have the carbs out of the bike I would pull the intake boots and replace the o-rings. Even if you think they are ok on a bike that old they are more then likely hard and brittle. And it doesn't sound like you would want to pull the carbs again to change them.

As much as I'd rather ride than wrench (although I do enjoy the wrenching, as frustrating as it can sometimes be), I'm trusting the originals on this as they seem to be nice and pliable. I may be proven wrong, but if I have to pull the carbs again, so be it. That's part of owning the bike.

Hi, I also have an 85 550 and had to get it running after 5 or so years sitting. It sounds like your low speed/idle jets are plugged with crud, mine were. Also the larger tube leading to the rear of the bike goes to the smog cannister which may be missing and the smaller one is a drain which will catch gas leaking from the fuel level sending unit and rout it away from the hot engine. Good luck

Since you have the carbs out of the bike I would pull the intake boots and replace the o-rings. Even if you think they are ok on a bike that old they are more then likely hard and brittle. And it doesn't sound like you would want to pull the carbs again to change them.

I'm not sure I would have dug into the starter to clean all of that out. :-) it's just mud, it wouldn't have hurt anything really. By pulling the starter you've opened the crankcase to contamination, and started a potentional (though unlikely as it's an o-ring seal) oil leak.

The GSXR shock replacement is a non-permanant modification that brings HUGE benifits. Everyone wants to concentrate on making more power on a bike, when real speed comes from working on the suspension. Once you go GSXR you never go back. :-)

Yeah, guess it's the clean freak in me that had me pull the starter. I know it wasn't NECESSARY, but I was compelled to do it! :shock: I've blocked the crankcase opening with a clean towel to prevent any contamination. With any luck at all the oil leak won't happen as the seal looks good. If that becomes a problem, I'll just add it to the list.

I'm more of a finesse and cornering kinda rider, so I would definitely be after handling before I worry about more power. But, again, not until I get the bike road worthy in as close to stock condition as possible. Still, I'll keep the GSXR shock in mind.

[Nerobro]

I'm not sure I would have dug into the starter to clean all of that out. :-) it's just mud, it wouldn't have hurt anything really. By pulling the starter you've opened the crankcase to contamination, and started a potentional (though unlikely as it's an o-ring seal) oil leak.

The GSXR shock replacement is a non-permanant modification that brings HUGE benifits. Everyone wants to concentrate on making more power on a bike, when real speed comes from working on the suspension. Once you go GSXR you never go back. :-)

when you gonna pull that old outdated shock and step up to a new GSXR rear?

Hey! I thought "all original" was a good thing around here. ;-)

One thing at a time. I won't replace anything that I don't have to until I get this bike on the road regularly. No sense in spending money on performance upgrades if I never get it to idle.

Thanks for the clue in on the oil pressure sensor wire. I do think that I'll leave that alone until I finish with the larger issues.

it's an oil pressure sensor... tis all, mine looks about the same and until it breaks off completely... it's fine.

when you gonna pull that old outdated shock and step up to a new GSXR rear?

Are you talking about the braided wire just beyond the starter post or the little wire beyond that (just under the plastic tab)? The little wire looks like it is the oil pressure switch.


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It's the smallest wire in the pic. It feeds into a rubber boot on the other side of the oil line banjo's. You can see the outer jacket fray (to the left of the oil line banjo's and directly under the plastic tie). The fray appears more white/lighter than the rest of the wire.

[Steve]

Are you talking about the braided wire just beyond the starter post or the little wire beyond that (just under the plastic tab)? The little wire looks like it is the oil pressure switch.


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Pic Update/Project Album

See the whole album here.

If ya get a chance, take a peak at the most recent shots of the carbs, airbox boots, intakes, etc. and let me know if ya see anything of concern. From what I can tell, it looks like everythings in pretty good shape, but I don't have a whole lot of experience with these things.

Thanks for any insights you may have!

Frayed wire...

I found a frayed wire on top of the crank case and I have a couple of questions:

1) What is this wire?
2) Since only the outer jacket is frayed, how necessary is it to replace it? I'd like to replace it eventually, but my feeling is that right now I'd like to just get the bike running before dealing with this detail.