The Kawasaki GT550, a mid-sized motorcycle produced from the mid-1980s, holds a special place in the hearts of many riders. Known for its reliable engine and comfortable riding position, it's a classic that's still enjoyed today. However, like any vintage machine, the GT550 isn't immune to certain problems that owners frequently encounter. This article dives deep into the common issues plaguing the GT550, offering insights and potential solutions to keep your ride running smoothly.

Rust Never Sleeps: The GT550's Achilles Heel

One of the most significant challenges faced by GT550 owners, particularly those with bikes that haven't been meticulously maintained, is rust. This is largely due to the age of these motorcycles and the materials used in their construction.

  • Fuel Tank Rust: The fuel tank is a prime target for rust, especially if the bike has been stored for extended periods without a full tank of fuel and fuel stabilizer. Condensation forms inside the tank, leading to rust that can clog fuel lines and carburetors.
    • Solution: Regular fuel stabilizer use, keeping the tank full during storage, and using a fuel filter are preventative measures. For existing rust, tank cleaning kits (chemical or electrolytic) can be effective, though severely rusted tanks may require professional repair or replacement.
  • Exhaust System Rust: The exhaust system is constantly exposed to the elements and high temperatures, making it highly susceptible to rust.
    • Solution: Regular cleaning and application of high-temperature paint can help slow down the process. Severely rusted exhausts may need welding repairs or replacement.
  • Frame Rust: Rust on the frame can compromise the structural integrity of the bike. Check areas prone to water accumulation, such as around the battery tray and under the seat.
    • Solution: Wire brushing, rust converter application, and repainting are essential for addressing frame rust. In extreme cases, welding repairs might be necessary. Always consult a professional for structural repairs.

Carburetor Conundrums: Keeping the GT550 Breathing Right

The GT550's carburetors, while generally reliable, can suffer from age-related issues. Poor running, difficulty starting, and rough idling are often signs of carburetor problems.

  • Clogged Jets: Over time, fuel residue can accumulate in the carburetor jets, restricting fuel flow and causing performance issues.
    • Solution: Thorough carburetor cleaning is essential. This involves disassembling the carbs, cleaning the jets and passages with carburetor cleaner and compressed air, and reassembling them with new gaskets if necessary.
  • Sticking Floats: The floats control the fuel level in the carburetor bowls. If they stick, they can cause fuel overflow or starvation.
    • Solution: Inspect the floats for damage or debris. Clean the float needles and seats, ensuring they move freely.
  • Vacuum Leaks: Vacuum leaks in the intake manifolds or around the carburetor boots can disrupt the air-fuel mixture, leading to poor performance.
    • Solution: Inspect all vacuum lines and intake components for cracks or damage. Replace any worn or damaged parts. Using a carburetor synchronizer can also help balance the carburetors for smoother running.

Electrical Enigmas: Taming the GT550's Wiring

Like many older motorcycles, the GT550's electrical system can be a source of frustration. Wiring can corrode, connections can loosen, and components can fail.

  • Corroded Connections: Corrosion on electrical connectors can cause intermittent problems, such as lights flickering or the engine not starting.
    • Solution: Clean all electrical connections with a wire brush and electrical contact cleaner. Apply dielectric grease to prevent future corrosion.
  • Faulty Rectifier/Regulator: The rectifier/regulator converts AC voltage from the alternator to DC voltage and regulates the voltage to prevent overcharging the battery. A faulty unit can lead to a dead battery or damaged electrical components.
    • Solution: Test the rectifier/regulator with a multimeter. If it's not functioning properly, replace it. Consider upgrading to a modern solid-state unit for improved reliability.
  • Wiring Harness Issues: Over time, the wiring harness can become brittle and cracked, leading to shorts or open circuits.
    • Solution: Carefully inspect the wiring harness for damage. Repair any broken wires with solder and heat shrink tubing. Consider replacing the entire harness if it's in poor condition.
  • Ignition System Problems: Problems with the ignition coils, spark plugs, or ignition module can cause misfires or difficulty starting.
    • Solution: Check the spark plugs for wear and replace them as needed. Test the ignition coils with a multimeter. If the ignition module is suspected, consult a qualified mechanic for testing and repair.

Suspension Sagas: Restoring the GT550's Ride Quality

The suspension components of the GT550, like any motorcycle, wear out over time. This can lead to a bouncy ride, poor handling, and reduced braking performance.

  • Worn Fork Seals: Leaking fork seals are a common problem on older motorcycles. This can cause oil to leak onto the front brake rotors, reducing braking performance.
    • Solution: Replace the fork seals and dust wipers. Inspect the fork tubes for damage and replace them if necessary. Consider upgrading to heavier fork oil for improved damping.
  • Worn Rear Shock Absorbers: The rear shock absorbers can lose their damping ability over time, leading to a bouncy ride.
    • Solution: Replace the rear shock absorbers. Consider upgrading to aftermarket shocks for improved performance and adjustability.
  • Stiff Suspension Linkage: The suspension linkage can become stiff due to lack of lubrication or corrosion.
    • Solution: Disassemble the suspension linkage, clean and lubricate the bearings, and reassemble. Replace any worn or damaged bearings.

Braking Blues: Ensuring Safe Stops on Your GT550

The braking system is crucial for safety. Problems with the brakes can compromise stopping power and increase the risk of accidents.

  • Sticking Calipers: The brake calipers can stick due to corrosion or debris, causing the brakes to drag or not release properly.
    • Solution: Disassemble the calipers, clean the pistons and bores, and replace the seals. Lubricate the caliper pins and ensure they move freely.
  • Worn Brake Pads: Worn brake pads reduce braking performance and can damage the brake rotors.
    • Solution: Replace the brake pads when they reach the wear limit. Use high-quality brake pads for optimal performance.
  • Contaminated Brake Fluid: Old or contaminated brake fluid can cause the brakes to feel spongy or not work properly.
    • Solution: Flush the brake system with fresh brake fluid every two years. Use the correct type of brake fluid as specified in the owner's manual.
  • Warped Rotors: Warped brake rotors can cause vibration when braking.
    • Solution: Have the brake rotors resurfaced or replaced.

Engine Ailments: Keeping the GT550's Heart Healthy

While generally robust, the GT550 engine can experience issues related to age and maintenance.

  • Oil Leaks: Oil leaks are common on older engines. Check for leaks around the valve cover, oil pan, and crankshaft seals.
    • Solution: Replace the gaskets and seals as needed. Ensure the surfaces are clean and properly prepared before installing new seals.
  • Worn Valve Guides and Seals: Worn valve guides and seals can cause oil consumption and smoking.
    • Solution: Have the valve guides and seals replaced. This typically requires removing the cylinder head.
  • Low Compression: Low compression can indicate worn piston rings or valves.
    • Solution: Perform a compression test. If compression is low, consider an engine rebuild.

Frequently Asked Questions

  • Why is my GT550 hard to start? Likely causes include a weak battery, clogged carburetors, or a faulty ignition system. Check these components and ensure they're functioning correctly.
  • My GT550 is running rough. What could be the problem? This could be due to clogged carburetors, vacuum leaks, or worn spark plugs. Start by cleaning the carburetors and checking for any vacuum leaks.
  • How often should I change the oil on my GT550? It's recommended to change the oil every 3,000 miles or once a year, whichever comes first. This helps to keep the engine running smoothly and prevent wear.
  • My battery keeps dying. What could be wrong? Possible causes include a faulty rectifier/regulator, a parasitic drain on the battery, or a worn-out battery. Have the charging system tested to identify the problem.
  • Where can I find parts for my GT550? Many online retailers specialize in vintage motorcycle parts. You can also check with local motorcycle salvage yards or online forums for used parts.

Keeping Your GT550 Alive and Kicking

Owning a Kawasaki GT550 is a rewarding experience, but it requires dedication to maintenance and repair. By understanding the common problems and addressing them proactively, you can keep your classic bike running smoothly and enjoy many more years of riding. Regular inspections and preventative maintenance are key to preserving the GT550 for future generations of riders.