BushcrafterQC

Mesure the voltage drop between the positive lead to the starter and the + battery terminal. If its under 200mv when starting don't worry about changing the cable.

haha yeah well i think it was a combination of both jetting and the coil. The choke circuit was blocked anyway on all 4 :p at least i know the bike alot more now!

YES! ITS FIXED and runs like a dream. Man is this bike smooth. i'm used to 650 thumpers and this feels really nice! It was the ignition coil after all. Put a new bar and mirrors on it. The P.O. was going for a cafe racer look, but I prefer this stance and actually seing whats behind me. Thanks yall for the help!

*Update* I got the carb rebuild kits. Got everything back together and doubled check everything was good, floats etc... The choke circuit was unclogged after sitting 3 days in acetone. 1 day didn't cut it. fuel level sender Fuel leak has been repaired, very happy about this. i used a little Permatex grey fuel resistant sealant on it. new plugs in. The bike started up really well with the choke fully engaged. revs up to 3-4k with the choke on. Warmed up, it wont hold its idle very well and dies out or surges sometime. I went for a small 2 min road test and it ran better then it ever has for the first 2 minutes, then, once warm, it lost all power and I barely made it back, died out on me in the driveway. I checked for vaccum leaks with carb cleaner, didn't find any. I got the carbs synced but they werent that much out of sync. no difference. Plugs 1 & 4 are fouled, 2&3 have a nice white/slighty brown tint. I'm starting to think maybe theres something wrong with the ignition... because 1 & 4 are run off the same coil. I will look up what i can check about this system. I have a spare coil i might try out. All secondary and primary coils show the same resistance. Maybe cdi is faulty?

I ordered these seals http://www.nichecycle.com/ncs/categories/carburetor/oe-style-replacement-parts/48-5040-mikuni-bs34-choke-plunger-dust-seal-by-ncs.html they are for the bs34's, not shure at all if they fit, i'll let you know if they do.

Did you find the dust seal anywhere? mine are torn also

as it turns out i didn't check the carbs well enough, choke needle passage ways are clear, but all 4 passages for the choke in the float bowls are 100% clogged. I tried carb cleaner, compressed air, even needles and jet brushes. Can't get the damm passages open! any trick i could try? thanks! -Also does anyone have a part number for the choke plunger seal? one of them is wrecked. -Also looking for plugs for the pilot jets, mine still look functional but are starting to dry up a little.

Tank was cleaned and coated by P.O. and looks OK to me. The fuel petcock filter are in good condition, looks like the P.O put a new petcock. He also installed a inline clear fuel filter. But uppon closer inspection, thanks to you, I just realized that its a FAKE filter... what the hell. dont cheap out filter folks! hahahaha made of video of the filter in question. Thanks for the input bud! as mentinoned previously i did everything you are recommending, but the jets looks like they might have been tempered with, just waiting on parts from fortnine to rebuild the carbs with correct jet size and new gasket as the old ones are shot. Looks like the P.o troughtly cleaned the carbs but i will be double checking all passage ways again before putting them on for the 7th time :p

It worked! getting a nice smooth resistance reading, tested on the bike and it looks very accurate. Now to find the right sealant to use to plug that dried up o-ring where the signal wire comes out....

Update**** Still waiting for the carb kits soo I'm looking at the small fuel leakage i havew from the tank. looks like the fuel level sendor gasket is shot, might be leaking trough the unit itself. The sender was sending out a bad signal too, wouldn't give the right reading. Dismantled it and it looks very corroded. These parts are not avaible anywhere near here (Québec Canada), so i will try and find a gasket and give the brush and contacts a good clean, hopefully it helps a little. Wish i could still order a new unit from suzuki :p.

@TonyGee Here on this website they list stock jetting sizes https://www.jetsrus.com/a_jet_kit_street/a_jet_kits_street_selection.htm#suzuki

totally got mixed up, that guide doesn't list jet sizes, i found them on a website. will try and remember which one. sorry

Clymer manual dosn't even list jet sizing but I found this guide that list jets for al BS carbs on suzuki https://drive.google.com/file/d/1oqEjoQyS9F3xSr2-15yDZILxt7KzQje7/view?usp=sharing

ive got a clymer, but theres no specs on it for needle adjustment, i'm guessing they might not be stock. I'm going to give up on it for now and wait for the parts to get my head clear on whats really going on here. i hope k & L jets aren't garbage :p Ill post an update when they are back on. thanks for all the feedback!

No noticable difference with the air filter removed. What position should the clip on needle be for stock jets and airbox?

well now i can't get it run much at all even cold, dies out at 3k, plugs aren't saying much #4 is a little wet and header is colder then others... Ran it for about 4 min before it wouldn't respond to throttle and died out good idea, theoretically i thought the jets i put back in where stock, but theres no telling if the PO drilled those as well, they looked way smaller then the drilled ones i removed when i removed the pods.

for a bit i was running on 3 cylinders at one point (i would unplug the lead on cyl #4 with a colder header and no difference in RPM) That plug was dry with ash deposits. Then I ran it some more cold and they all came out black. I'm going to clean them right now and run it for a bit and check them gain to post a picture. All jets are supposed to be the standard sizes, 92.5 main 40 pilot and 150 air. But the previous owner might have tempered with them. I'm waiting for some new ones in the k&l car rebuild kits. I reinstalled the OEM airbox beacause the P.O had pods on it. I removed the jets he installed and put some that where in a box of stuff that came with the bike.

I think it actually ran soo rich it fouled the plugs, and thats why it won't start. I guess I'll have to wait until i get the new jets to ride . Does anyone know where I can find the specs for the needle height for bs32? I'm pretty shure someone messed with those. I just need to find long enough circlip pliers to take them appart, mine are too short.

Well it might of been to good to be true :p. It was running fine yesterday for a small ride, air was cool. Today is hot and It ran real nice when the engine was cold (starts without the choke on the first turn over) but as soon as the engine warmed up it lost power died on me. wouldn't start until i waited 5 min for it to cool off a bit. had it surge on me a few times too. This time when i put the carbs back together the float bowl gasket looked kind of terrible. no fuel leaks though. Caant wait for the postman to come with the k & L kits. hopefully thats all i need. I'm worried something else is going on here... newplugs look like this. They look rich right?

Update**** I put the beat up oem mikuni pilots jets with 6 holes back in. readjusted the float heights, 3 where 2mm off. And fixed the stripped screw treads for the float bowl with an M5 helicoil. She's up and running! finally will get to ride it now. its running way smoother then when i bought it. Still has a few hick-ups here and there. adjusting the pilot screws doesn't seem to have any effect. I suspect there still another small vaccum leak somewhere. I will wait to receive the k&l kits to take the carbs off again and change the old seals. meanwhile i'm going to have some fun and see where it can bring me starting to get a feal for these old carbs. its fun. Happy i didn't go out to a dealer and buy a modern bike.

Hey i found this guide for the Gs550 carbs. I'm strugling with mine. cant get the bike to start anymore. hope this helps! https://drive.google.com/file/d/1oqEjoQyS9F3xSr2-15yDZILxt7KzQje7/view?usp=sharing

I got the carbs out and switched over to main jet 92.5 and pilot 40. The new pilot have 8 holes instead of 6. Back on the bike with the OEM airbox installed and I cant get it to start. I tought that with the stock size jets and airbox it would run fine but it wont budge. played with different pilot air settings. I got it to run for barely 2 seconds thats it. sounded like only 1 cylinder got running for a moment. got a big back fire. I wonder if the extra holes on the new pilot jet is causing the issue. Maybe something else on the carb was modified by the PO.... not shure. I really tought getting the stock jet size and removing the pods would solve this. I was running with the pods and drilled jets but, not all cylinders and was very rough

Shure did, Thanks for the infos

sorry for all the questions but with these vaccum petcocks, if it still lets a little fuel go trough when on ON position without getting vaccum. Could this cause any problems? thanks

Anyone knows what this fitting is for on the fuel level sender? is it just a vent? its not plugged to anything, im guessing it vents in the stock airbox. I will probably find a generic hose to connect it to it.