81 Suzuki 550T build

Beaner242

Been Around the Block
Picked this bike up cheap after it had been setting for years. Previous owner could not get it to fire so he stripped the harness to re-do it. I have bike mostly back together and after much tracing and looking cross eyed at the wiring schematic, I cant get it to turn over with the starter button. I have all the wires labeled and hooked back together minus blinkers and gauge lights. Problem is I cant get it to turn over using the starter button, if I cross the solenoid the starter will turn over but that is the only way. I've traced all wires and thought maybe it was the clutch switch on the handle bars but that has been eliminated all together and still nothing. Took the start button apart and cleaned contacts, nothing! I checked all the fuses, used a tester to make sure current is getting to the ignition switch, nothing! Swapped ignition switches, nothing! Moved some ground wires from battery to the frame, nothing! Voltage at coils is good with key on, nothing! Headlight works. No horn to check yet. What am I overlooking here? It has to be something simple I just cant find it. What to do before abandoning the factory harness and re wiring the whole thing? Any help would be greatly appreciated, I been working on this thing for 2 days and cant get it to turn over? :'(
 
Yes Mechdesign, with my cheap meter I am getting between 14-15 volts at the starter button on the orange w/white wire. Should the green and yellow wire coming of the solenoid have any voltage running through it with the key on?
 
OK. got the button thing figured out. Now the problem is gas pouring out of carbs on the filter side. I set the float levels per the instructions I got on basscliffs website which was 7/8th of an inch. looking in the Haynes manual I got it says 1.02 inches? which one do I go by? What is the correct height for the floats?
 
Back
Top Bottom