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Engine idle = fine, Throttle = Stall (also an air filter question)

  • Thread starter Thread starter mwa423
  • Start date Start date
M

mwa423

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Hey everybody, working on getting my 81 gs650g back on the road and now that I have a battery and all that good stuff so I fired the bike up and it ran a little rough the engine was racing (sadly the tach seems to be disconnected so I don't know how high) and once it got a bit warmed up it was idling fine. But whenever I give it some gas it would stall out. Any idea?

Now the air filter question: It's a shaft drive bike and I picked up an air filter (supposedly universal, including the suzuki gs650) but it looks nothing like the air filter in the clymer manual and it really doesn't fit anywhere on the bike. Any idea (would pictures help) And also how badly would no air filter affect the engine running?

Last but not least, I have disassembled my master cylinder and I can't get the piston out. If I could do that, I figure a rebuild would be pretty straightforward (a new cup and I'm good on the rest, new fluid etc. All the o-rings and such look good) I have tried sticking things in to pop it out, I have tried needle nose pliars pulling it out. Any ideas?

As always, thanks for your help all!
 
mwa423 said:
Hey everybody, working on getting my 81 gs650g back on the road and now that I have a battery and all that good stuff so I fired the bike up and it ran a little rough the engine was racing (sadly the tach seems to be disconnected so I don't know how high) and once it got a bit warmed up it was idling fine. But whenever I give it some gas it would stall out. Any idea?

Now the air filter question: It's a shaft drive bike and I picked up an air filter (supposedly universal, including the suzuki gs650) but it looks nothing like the air filter in the clymer manual and it really doesn't fit anywhere on the bike. Any idea (would pictures help) And also how badly would no air filter affect the engine running?

Last but not least, I have disassembled my master cylinder and I can't get the piston out. If I could do that, I figure a rebuild would be pretty straightforward (a new cup and I'm good on the rest, new fluid etc. All the o-rings and such look good) I have tried sticking things in to pop it out, I have tried needle nose pliars pulling it out. Any ideas?

As always, thanks for your help all!
Click to expand...

DO NOT RUN YOUR BIKE WITHOUT THE AIR FILTER!!!!No filter will cause engine damage! Your bike will run hot without the filter and when you go to give it gas it will die.Do not run it without the filter installed!Go to the dealer and order an air filter for it.It will come with oil already on it and needs to be cleaned and re-oiled periodically.Get a manual if you dont have one .The 650's are nice bikes and will run forever if kept up.I should know, I have an 83 myself,take a look!I cant help you on the stuck piston.hopefully somebody else will be able to help you.
 
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As said, your model is picky about the air filter and housing condition. Install the correct filter and see if it stalls with throttle.
If it still does, the first two things that come to mind, especially if the bike sat and the carbs dried up, is to clean the carbs and inspect the rubber diaphragms.
Dirty carbs will varnish up inside and the jets clog. If even one diaphragm gets a hole or cracks from age/hardening, that carb will idle OK but won't accept any throttle.
As for the MC piston, do you have the c-clip out? It can be hard to see but it's there. If removed, use some wood object to poke it out. Nothing hard or you can destroy the inside bore.
 
Thanks for the replies, where is the c-clip in the master cylinder? I sure can't find it.
 
mwa423 said:
Thanks for the replies, where is the c-clip in the master cylinder? I sure can't find it.
Click to expand...

The rear master cylinder can be tricky as it can be covered with rust and corrosion... I ended up just buying a new one on ebay it was ~$30
 
It's actually the front, and except for the stuck piston it's in great shape.
 
mwa423 said:
Thanks for the replies, where is the c-clip in the master cylinder? I sure can't find it.
Click to expand...
There has to be a c-clip or the parts wouldn't be held in.
After removing the rubber dust boot, you should see the c-clip immediately. Some clips require fairly long and narrow pliers/right angle pliers. They're easier to remove than to put back.
If you need to, try looking up a parts illustration at Bikebandit or? They have those pics.
 
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