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Message started by Don Sinclair on 01/12/06 at 19:08:03

Title: 2002 Savage will not start
Post by Don Sinclair on 01/12/06 at 19:08:03

Hope someone here can help me.
I bought a excell cond 4,000 mi savage(2002) a few months ago. I decided to do the carb mod suggested here to increase power and reduce or eliminate the backfire problem.
I followed all the instructions carefully including reducing the thickness of the white plastic spacer,adjusted the mixture,and put it all back together and it won't start !
I'm getting spark,got gas altho battery cranks a little slow. Any suggestion please. I'm so frustrated right now, I'm getting ready to sell and go back to moto guzzi's !! Don

Title: Re: 2002 Savage will not start
Post by SAMM on 01/12/06 at 19:13:47

Pull the fuel line off at the carb and see if you are getting any fuel in any petc0ck position...If you have fuel, tap on the float bowl to reset the needle and seat..

Title: Re: 2002 Savage will not start
Post by SAMM on 01/12/06 at 19:15:18

And charge that Battery !!!

Title: Re: 2002 Savage will not start
Post by pgolden on 01/12/06 at 19:15:49

Did you replace the vacuum line. Thats what lets fuel flow from the petcock.

Title: Re: 2002 Savage will not startDon
Post by Don Sinclair on 01/12/06 at 19:19:55

Thanks for the very quick response. I'm going to charge the battery overnight on slow and check out the other suggestions in the morning. Thanks again

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/12/06 at 19:21:37

Your bike should start easier after the carb mods. You've obviously got something amiss with the carb - float level got moved, CV diaphram holed or top lip not in right, parts not put back in the right order.

Check the carb photos in the Tech Section here, or go to http://www.bikebandit.com or http://www.ronayers.com and study the parts fische. If you have a manual, study the carb diagrams.

I can assure you, working on a Savage is a whole lot easier than working on a Moto Guzzi ;D

Title: Re: 2002 Savage will not start
Post by SAMM on 01/12/06 at 19:22:54

I used to know a Don Sinclair...Are you in Portland??

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/12/06 at 19:28:57

SAMM wrote:

Pull the fuel line off at the carb and see if you are getting any fuel in any petc0ck position...

Fuel should flow freely out of the disconnected fuel line in the "Prime" position. This doesn't require vacuum and is always on. You can and should use the Prime position while trying to get your bike started.

Once you have your problems sorted use the ON and Reserve positions. They work in an automatic fashion using engine vacuum to turn on and off. The ON and reserve positions have been known to malfunction on these petc0cks.

Title: Re: 2002 Savage will not start
Post by Don Sinclair on 01/12/06 at 19:43:37

I did not use "prime" position in trying to start it, but I'll try it.
I tried to align everything but I did have problems getting the lock plate screwed to the diaphragm .Real pain in the a**. The needle assembly seemed to work fine though.
No I'm not from Portland.. I live in Oceanside, Ca.

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/12/06 at 19:55:40

Don Sinclair wrote:

I did have problems getting the lock plate screwed to the diaphragm .Real pain in the a**.

I've been there. The trick to getting those screws in is to tape the screw to your screwdriver with a little electrical tape. It's a piece of cake, just don't lose the tape in the carb.

Title: Re: 2002 Savage will not start
Post by babbalou on 01/12/06 at 19:59:14

Don Sinclair wrote:

That should do it. I learned that trick the hard way after a jet change. Float bowl was empty & it was cranking 'till the battery was half dead. Put it on prime & it started right up.

Title: Re: 2002 Savage will not start
Post by Don Sinclair on 01/13/06 at 09:59:55

I charged my battery last nite and this morning I checked
the gas supply to the carb.it is getting gas ..it cranks over fine and but still
won't start !!
I noticed an older comment about there being a brass washer on the jet . I don't remember that when I replaced
with the 155. So I guess I'll check that next.
Have to go to work now so maybe Sat I'll try again.
So far , I have to say that my Guzzi is MUCH easier to work on ! At least the carb issue. Thanks again to all of you who have offered suggestions.

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/15/06 at 07:05:34

Don Sinclair wrote:

Guzzis are great bikes. I'd like to have one. But if you make a mistake when working on it, it might not start either :) Don't blame the bike ;D

Did you check to make sure that you DO have gas in the carb, as others have said?

Did you turn the petc0ck to PRI and check for gas flow to the carb at the bowl drain? A glass jar is useful when you do.

Are you sure that the floats were okay before you closed it up?

After you have another "unsuccessful attempt" to start the bike, check to see if you can smell any gas in the tailpipe.

If you forgot the washer on the main jet, that wouldn't prevent the bike from starting because the main has little to do with starting. I've also noticed that the washer can remain inserted in the carb when you remove the jet (hence, you wouldn't notice) so that may be a non-issue. I'd worry about it only if there is a problem after the bike is running.

Keep hammering away at it. The Savage is well known as an easy bike to maintain because it is built so simple. You'll probably slap yourself in the forehead when you find out why it won't start.

Title: Re: 2002 Savage will not start
Post by don Sinclair on 01/16/06 at 15:32:14

Ok Greg and others.
I am getting gas to the carb and I am "smelling" some gas
from the end of the tail pipe just after trying to start it again, but still no luck starting it.. It cranks over ok and headlite is bright. Any more suggestions before I start taking off the seat and all again to check whether the spk plug is wet and pull the carb off again. Thanks guys, Don

Title: Re: 2002 Savage will not start
Post by SAMM on 01/16/06 at 15:34:37

Time for a new spark plug !!! Go buy a couple they are cheap.........

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/17/06 at 05:49:12

I wonder. A plug isn't usually a problem. Do you open the throttle when you are cranking it?

Title: Re: 2002 Savage will not start
Post by Don Sinclair on 01/17/06 at 08:40:01

Yes , I gave it gas and tried with choke out as well as in.

I'm wondering if when I put the diaphragm assembly back together after I sanded down the white spacer that I might have installed the lock plate incorrectly.Somewhere else on this Savage site , I read that the holes align at 5 o'clock and 7 o'clock positions. I don't remember what position the holes were in ...I only recall that it took me a long time to screw the lock plate down.
Got Wed off so I'll try to get it running again then . I'm trying not to get discouraged about this. It's not brain surgery right? Don

Title: Re: 2002 Savage will not start
Post by torque on 01/17/06 at 08:44:35

seems to me like your getting way to much gas ,u better check your carb float,just to make sure its not stuck open.

Title: Re: 2002 Savage will not start
Post by Don Sinclair on 01/17/06 at 08:50:39

I'm not smelling lots of gas and not getting any gas leakage,and just a steady but light stream when I open the bowl drain screw. How can I tell if it (float) is sticking?

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/17/06 at 11:56:33

Don Sinclair wrote:

I'm not smelling lots of gas and not getting any gas leakage,and just a steady but light stream when I open the bowl drain screw. How can I tell if it (float) is sticking?

If you're getting a steady flow out the drain plug, your float is not sticking closed. With the bowl off and the fuel line connected turn the gas to prime. When the float is down, gas should flow. When you raise the float with your finger, gas flow should stop.

Check your diaphram to make sure it's installed correctly. There's a locating tab on the rubber and in the carb body. I found that to be the toughest part to reinstall. Use some grease in the channel if that helps you hold it in place while putting on the top. Tape the little screws to your phillips screwdriver with electrical tape to help reinstalling them.

Check the online parts fische and the photos in the Tech section here. Something is amiss and I'm guessing it's the CV diaphram.

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/17/06 at 14:55:42

Not to be insulting, but check the basics. Petcock lever pointing down, transmission in neutral, ignition on, clutch lever in, engine stop switch to run, and then hit the starter switch.

Make sure you have the vacuum hose connected to the petcock and carb.

If you decide to look at the diaphram again, you might want to disassemble it and start over. Maybe someone can check out the following to confirm that I remember it correctly.

The needle has, from the top, the spacer, the e-clip, a washer, and the spring.

The lock plate has a dimple which is installed down, toward the spacer. It actually sits on the spacer and hold the lock plate off the washer a bit. I have no idea why. The plate has two holes for the screws and three slots. One is at 2 o'clock, one at 6 o'clock and another at 10 o'clock. The 2 and 10 o'clock slots uncover two holes in the diaphram. Again I have no idea why they are there.

Finally the upper lip of the diaphram has a small tab that goes into a groove in the carb body. I assume that this locates the assembly in the correct position.

BTW, you might want to do the "spark plug door" mod so it will be easier to remove the spark plug in the future.

Steve

Title: Re: 2002 Savage will not start
Post by don Sinclair on 01/17/06 at 22:38:50

Steve, Thanks for that very complete answer. Tomorrow
morning I'm going to remove the carb and verify the parts layout as you describe. I really think that is the way I assembled it but no harm in reviewing it again. Thanks Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/18/06 at 14:53:49

Don,

Any luck with starting the bike?

Steve

Title: Re: 2002 Savage will not start
Post by Don Sinclair on 01/18/06 at 20:26:52

Steve,
Had to go in to work today but will be off Thurs aft and will try to get it going without having to take carb out of frame( drop fuel bowl and remove upper cover to remove diaphram and needle assembly in place). Thanks for your concern, Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/18/06 at 20:56:10

Don,

It's a shame how work gets in the way of progress sometimes, isn't it?

Steve

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/19/06 at 15:18:07

Progress( ?) report....
Ok, I've just checked the float and it works fine.
Ditto diaphram "lip positioning "
I'm on my way out to get allen screws to replace the cheap soft phillips head screws for fuel bowl . When I return ,I'll pull and disassemble the needle/spacer /plate combo. Don

Title: Re: 2002 Savage will not start
Post by SAMM on 01/19/06 at 15:38:19

Hey !!! Dont forget the spark plug !!!!

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/19/06 at 16:34:40

Just got the allen heads for the bowl.
Also checked the lock plate/screw positioning and it is just as Steve has said including the dimple down so I'm reluctant to take that all apart but I will since everything else so far checks out up to here. don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/19/06 at 17:35:19

Sounds good so far. Were the holes uncovered on the diaphram?

Did you also check the new jet to assure the washer is in place?

Steve

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/19/06 at 18:22:22

Don, you are sitting on the bike with the kickstand up while trying to start it ? Kickstand down kills the ignition - it's a safety feature. You shouldn't have to give it gas. If it's cold use the choke.

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/19/06 at 18:40:57

Bob

Mine will start with the sidestand down. I do have to pull in the clutch lever.

Steve

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/19/06 at 20:26:59

Steve and others,

The holes were uncovered and line up with the throat area (diaphram) of the carb as it should , I think.
I have not yet taken the jet out to check for dirt or lack of washer. Due that tomorrow morn.
Prior to start attempt ,kickstand has been down,clutch in .
Now , I'm wondering if I connected the vac hoses properly.
As I recall, there were 2 hoses about same size remaining after I hooked it back up originally .One apparently from the smog device which I joined with another hose from under the gas tank.The other hose which also seemed to come from rear of the bike which I fitted to the carb vac tube. Is it possible that these hoses need to be reversed?
Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/19/06 at 20:39:59

Don,

Do you have a California model?

On my bike, there are two hoses that come from just above the main bore. These are bowl vents. They go up under the tank and just lay there.

The hose that may be a problem is the hose that runs from the bottom of the petcock to the right side of the carb. On my bike, this vacuum hose has a wire guard (like the speedo cable). This hose supplies the vacuum that operates the petcock. If it is not connected, the bike will not get enough gas to run if the petcock is in the run or reserve position (ask me how I know). The "PRI" position supplies gas without the vacuum.

So if you turn the petcock handle so that it points to the "PRI" gas will be supplied without the vacuum hose connected.

Steve

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/19/06 at 21:02:49

Yes Steve, It is a Ca model .
Re : the carb vent hoses...yes I found out that they just hang down and do not relate to the vac for the carb .
Also the hose that runs from the petthingy to the other side of the carb is properly attached.
I think I'm running out of things to check but I'm also learning( but I sometimes wonder if Im' ever going to hear this thing fire up again !)
Thanks for the continuehttp://suzukisavage.com/bbs/YaBBImages/rolleyes.gif
Roll Eyesd support. I'd not going to let this little problem get to me. Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/19/06 at 21:05:01

If it was running before it will run again!

Just keep chipping away at it. :)

Steve

Title: Re: 2002 Savage will not start
Post by Reelthing on 01/19/06 at 21:10:23

don sinclair wrote:

you have all the fuel going - you have a spark? lay the plug on the head and hit the button - it spark?

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/19/06 at 21:50:24

Reelthing wrote:

you have all the fuel going - you have a spark? lay the plug on the head and hit the button - it spark?

Even better - if you haven't done the plug door mod...hook up a spare plug to the coil wire and lay it on the cylinder head and check for spark. DO NOT put your hand anywhere near the plug while cranking :o I did this ONCE on a lawn mower and learned that lesson the hard way.

Don, it sounds like your carb is in order if you haven't changed the float level by accidently bending the float. Try switching those vacuum hoses and check your spark. Trying to start it with the stand up will eliminate any doubt about that safety switch. Fellas I'm wondering if there's anything else electrical which might be preventing this bike from starting (wiring, fuses, etc.).

Keep the faith Don. Your bike will run again ;D In fact it will run way better with the new carb jetting.

Title: Re: 2002 Savage will not start
Post by Reelthing on 01/20/06 at 07:56:53

was just wondering about the spark - if it didn't have any - you bet - start going through the connections under the seat - and the push on wires at the coil - but if it's got a hot spark we may to think on this a bit

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/20/06 at 10:30:16

Friday report,
Ok , took seat off ,made spark plug" door modification", and checked for spark .. ok but not super strong...battery may need another charge, took out my new 155 main jet and yes it does have the washer,sprayed the underside liberally with carb cleaner.
Again work calls so have to stop for today. Over and out, Don

Title: Re: 2002 Savage will not start
Post by pgolden on 01/20/06 at 10:40:55

I wish I could go fix his bike!

Title: Re: 2002 Savage will not start
Post by torque on 01/20/06 at 10:51:39

i know whatcha mean,i'm ready to get my hands dirty ;D

Title: Re: 2002 Savage will not start
Post by SAMM on 01/20/06 at 10:58:22

He lives in Oceanside Cali. Long way for me to go.....
Maybe someone wants to make a trip to Disneyland !!!

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/20/06 at 11:09:22

Don Sinclair wrote:

How about with the throttle closed and the choke at 1/2? There is no need to open the throttle to start the bike.

In all your tinkering, has your plug not worked or ever come out wet? I still think it is gas.

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 01/20/06 at 11:42:16

Greg_650 wrote:

How about with the throttle closed and the choke at 1/2? There is no need to open the throttle to start the bike.

Just to note: In many cases where an enrichener is used instead of a choke (as I believe the case is with the stock BS40 Mikuni carb, definitely with the Amal Mk2), twisting the throttle bypasses the enrichener circuit and renders it useless.

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/20/06 at 15:21:30

pgolden wrote:

I wish I could go fix his bike!

I bet Don wishes you could go fix his bike, too. :)

Steve

Title: Re: 2002 Savage will not start
Post by Don Sinclair on 01/20/06 at 20:24:37

Ok Guys( and girls too),
Guess it's time to invite all who are interested to a "bike starting "party !!
I'll supply the food and beer..and if, no when you get my bike started welll.... more food and beer ??. Sorry I cannot pay your plane ticket. Bye the way,I am the only one in this group from Southern Cal ??
Back to the bike, I'm really thinking that I may just need a new battery. Even when freshly charged, it has not cranked over very fast and since I recently bought the bike, I don't know how old it is. So, since I 'm pretty cheap ,where can I get the best deal on a Savage battery? Does Walmart for example sell something that will work ? Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/20/06 at 21:04:14

Don,

Is the decompression working?

Steve

Title: Re: 2002 Savage will not start
Post by SAMM on 01/20/06 at 22:27:53

I feel like the Aflac duck....Buy a Spark plug.....Mine wouldnt start after the white spacer mod.(not sure why)....I charged the bat, put the petc0ck on pri and it fired rite up !! The OLD plug had been gas fould to the point of never starting...

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/21/06 at 10:24:10

New sparkplug got it... and tried it already. no luck.
Steve, Decompression working? ...how to check it ?
My brother who is more into mechanics than I am (but lives 2000 miles a way) says that I should spray a small amount of starter fluid into spark plug hole then quickly put plug in and see if it fires. That seems a little dangerous to me. What do you guys think ?
I work mostly weekends now so can't get back to it until Monday. Don

Title: Re: 2002 Savage will not start
Post by Reelthing on 01/21/06 at 13:57:23

That seems a little much a tiny bit in the air box shouldn't hurt it - but nor should you need to - you seemed in doubt about the bat'ry sure won't hurt to know you had a new one

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/21/06 at 17:02:02

Don,

The decompression solenoid will click when the starter is pushed. You should hear this before the starter kicks in. A strong click or clunk.

I don't know if the engine will even turnover if the decompression is not working, but if it does I assume it will turn over slow.

There is an adjustment, but what I'm thinking is you may have inadvertently disconnected the timer module or or pinched a wire. The module is under the tank.

You might also want to check under the tank to see if there are any other disconnected wires.

Steve

Title: Re: 2002 Savage will not start
Post by Dynobob on 01/22/06 at 02:36:19

Reelthing wrote:

you seemed in doubt about the bat'ry sure won't hurt to know you had a new one

I agree. If the battery is suspect, replace it.

Perhaps you could ship your carb to someone that has removed their airbox (not I) and has easy carb access to make sure it's working properly. Or possibly someone has a known working carb and could provide you with a loaner.

I'd avoid the starting fluid. That stuff is pretty nasty and kinda hard on motors. Maybe just put a tablesp00n of gasoline down the plug hole.

Edit: LOL it wouldn't let me type tablesp00n. Doh ;D

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/23/06 at 12:32:47

don sinclair wrote:

New sparkplug got it... and tried it already. no luck.

To you and everyone else that pulls the plug the minute there is a problem....

Na, Na, I told you so!

When is everyone gonna learn? Nine times out of ten, you change the plug plus do a dozen other things, and then you figure the plug fixed it.

My plug is 3 years old, and even then I didn't need to change it. Stop wasting your time and money.

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/23/06 at 12:34:30

Savage_Rob wrote:

Good point, but some people think they have to open the throttle to start it.

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/23/06 at 12:36:49

Steve530 wrote:

Don,

Is the decompression working?

Steve

Compression is always working. It's a matter of how much compression is working :P

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/23/06 at 12:41:14

Have you checked yo see if you have a potato in the tailpipe?

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/23/06 at 14:03:06

Greg_650 wrote:

But at $1.49 per spark plug change, it's not a lot of money. :)

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/23/06 at 18:43:27

Progress (?) report:
No potato in the tailpipe ....
Decompression solenoid is working ....
In the morning , I'll put everything back together with the old plug( because it DID run with it) and give it another try.
If it does not start then I' ll buy a new battery and see it that does the trick. Thanks for your support . Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/23/06 at 19:10:39

Keep us posted.

Title: Re: 2002 Savage will not start
Post by pgolden on 01/23/06 at 19:39:22

The first thing I do when I get home from work is to check if Don has got his bike started. When he gets it running I guess I'll have nothing to look forward to.

Title: Re: 2002 Savage will not start
Post by SAMM on 01/23/06 at 19:44:36

Maybe he is pulling our chain ?? ;D

Title: Re: 2002 Savage will not start
Post by klx650sm2002 on 01/24/06 at 01:30:39

The choke on My old Z550 was a choke with a hinged flap in it, FCR is an enrichener. Standard KLX carb (Keihin CVK 40) is also an enrichener.

Clive W :D

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/24/06 at 05:58:10

Steve530 wrote:

But at $1.49 per spark plug change, it's not a lot of money. :)

Why do it anyway? If you have a problem, the process of "troubleshooting" never involves simply changing parts until it runs. You only change a part when you find that it is bad. That is what the "stealers" do to save time, but you pay for it.

For example, IF you have no spark do you realize that you can use a 6 MM bolt on the end of the plug wire to check for it? Electricity doesn't know the difference and then if you have no spark, the plug is still good. Put it back and follow the path upstream.

2 times to change a plug....1) Bad Plug, or 2) Routine maintenance (burned electrodes, carbon, etc.).

Most of use have manuals of one kind or another. Where in the troubleshooting section does it simply say, "Bike won't start: Change plug"?

Same goes for the battery issue...there's a lot of talk about The battery MIGHT be bad. What is the first thing the manual says Change Battery? Or does it say Test Battery?

Get a meter and test the battery. Go by the book and meters are real cheap. Then if the voltage is correct and it still won't start, take it to a bike shop and have them give it a load test. They do it for free.

The hardest part about all this is that people don't want to take the time to learn something. Trust me, once you go through the proper steps in the manual you'll fix the problem and buy fewer parts.

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 01/24/06 at 06:05:06

The load test can definitely be important. My battery had the correct voltage but failed the load test at Sears (they also test them at no charge).

Title: Re: 2002 Savage will not start
Post by torque on 01/24/06 at 07:05:43

ok,someone might have said something like this,but i'm just making sure.

ok,u said u have spark and the engine turns over,and the decompression solnoid is working.so to me it seems like a fuel supply issue,u said u have gas at the carb,but what about in the engine,after u try to start the bike,is the spark plug really wet,or completely dry?

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/24/06 at 08:25:20

torque wrote:

Exactly, and I'll refer you to my reply #42 as well.

Just remember that if a bike system is mechanically correct, it only needs 3 things...Air, Fuel, and Ignition. After you narrow it down, what is missing?

My question about smelling the tailpipe was just a hint. A tailpipe probably smells a little like gas anyway, but if the carb is working correctly, it should smell strongly of gas after a failed start.

Title: Re: 2002 Savage will not start
Post by Greg_650 on 01/26/06 at 23:10:43

Well? Progress report? Any luck? Too busy ridin' for an update?

Title: Re: 2002 Savage will not start
Post by don sinclair on 01/27/06 at 01:51:15

Greg.... others,
Left work early Tues.. felt like crap.. still do ..
probably got the flu bug. All I've been doing is resting , drinking lots of water and watching way too much bad daytime tv. I have no desire to work on the bike or anything right now. Don

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 01/27/06 at 06:01:10

Ack! Tequila, lots of tequila...

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/27/06 at 15:14:06

Don,

Hope you feel better soon.

Steve

Title: Re: 2002 Savage will not start
Post by pgolden on 01/29/06 at 16:30:33

You can work on that bike with the flu. Come on let's get this puppy running.

Title: Re: 2002 Savage will not start
Post by Steve530 on 01/31/06 at 18:23:37

Bump for Don's flu bug.

Title: Re: 2002 Savage will not start
Post by Trippah on 01/31/06 at 18:41:32

Don- I've always wanted a guzzi- love the 750 Breva.. :D You didn't actually say so, but I presume the sav was running before the carb mod, yes? If so, I always go baack to the last component I worked on (Err improved?). Sort out the carb and its connections again before going too far afield. Hope the bug leaves you alone soon..seems like every one is catching something.

Title: Re: 2002 Savage will not start
Post by Steve530 on 02/06/06 at 15:28:15

One more bump. Let's see if Don is still around. :)

Title: Re: 2002 Savage will not start
Post by jcbass7 on 02/15/06 at 17:08:22

reading this thread reminds me of watching a catchy tv show.. its reaching the climax and im soo anxious to find out the results! haha good luck with the bike, im going to tackle mine this spring.. got it last fall but it had sat around for about 6 years and now needs a lot of help to run.. had it putting a bit before but i beleive my carb needs som cleaning etc.

goodluck and get better so you can ride again!

Title: Re: 2002 Savage will not start
Post by Zniper175 on 02/16/06 at 19:17:40

Oh my frieken God. I still can't beleive I read all the way to the end and the bike is still broken.

lol

Will someone fix the TV so I can finish the show?

Title: Re: 2002 Savage will not start
Post by don sinclair on 02/17/06 at 12:37:59

To everyone !!!
Yes I'm still alive and the Savage.....SHE RUNS!!!!!!!!
After a nasty bout with the flu .(and taxes), I'm here to tell you that the problem is solved. Those who said check intensity of spark were right. I bought a NEW battery and she started right up !!!With the aftermarket Jardine muffler, I'm sure my neighbors arent so happy but I am.
At times I never thought I would hear the bike run again.
Idled really fast so I adjusted throttle down but she still backfires !!
I don't have the seat on yet so i don't know about performance but it should be better with the white spacer sanded down to 1/2 stock thickness and main jet changed to a 157. Gotta go to work now. I'm one happy dude tho!!
Thanks again to everyone who helped me with this . Don

Title: Re: 2002 Savage will not start
Post by Dynobob on 02/17/06 at 15:38:14

don sinclair wrote:

Yes I'm still alive and the Savage.....SHE RUNS!!!!!!!!

Great news Don. It's crazy that the battery crapped out at precisely the same time as you rejetted the carb. Congratulations on getting it sorted. Let us know how the big single runs with the new jetting. I think you'll be impressed.

Title: Re: 2002 Savage will not start
Post by don sinclair on 02/20/06 at 18:53:12

I took the bike out this afternoon....it runs better than ever...faster than I ever thought it could be with the carb mods and Jardine muffler( 1/2 white spacer,157 main jet, and 2 1/2 turns out from idle.) It really feels like a different bike. It winds up to 65 fast and wants to keep pulling hard !!What fun !! Now I need to put on new brake pads so can stop the thing.
Only downside is the single backfire at shut off...sounds like a single gunshot.
Thanks again to this great list who helped me with my many earlier frustrations. Don

Title: Re: 2002 Savage will not start
Post by Kropatchek on 02/21/06 at 05:01:00

don sinclair wrote:

IOnly downside is the single backfire at shut off...sounds like a single gunshot.
Don

That's the famous Savage fart, I like it. 8)

Greetz
Kropatchek ;D

Title: Re: 2002 Savage will not start
Post by Steve530 on 02/21/06 at 05:32:02

Don,

Glad you got it running and it was nothing more than a battery.

I've rejetted, cut the spacer, and added a Dyna muffler and I get a backfire on shutdown, too. Complete with a nice blue flame. I thought I might need to adjust the exhaust valves. I guess not, but I'll probably check it anyway.

I noticed a big increase in power with the mods, too. You might think about the K&N filter. I used a K&N drop-in and removed the airbox snorkel. Since I did this and the mods at the same time, I can't tell if there was an gain witht eh K&N, but the overall effect was great.

Steve

Title: Re: 2002 Savage will not start
Post by pgolden on 02/21/06 at 07:13:39

This is the news all of us wanted to hear. Go ride and have fun!

Title: Re: 2002 Savage will not start
Post by Don Steel on 02/23/06 at 05:28:14

Hi Guys,

I have been following this saga all the way in good old Great Britain!
It has been a compelling read, and I am glad you got it started Don!
I have owned a Savage for around 7 years, but it has stood in the garage for around 5. I have just stripped it down for a total renovation, so I am looking forward to trying all the mods that are on your site.

By the way, the Savage was never really a big seller over here, so parts can be a bit hard to find! The American ones have a better tank decal than ours, that looks more of a custom item!

Thanks for a good site!

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 02/23/06 at 05:37:04

Don Steel wrote:

Gary (gazab44 (http://suzukisavage.com/cgi-bin/YaBB.pl?board=;action=viewprofile;username=gazab44)) may have some ideas on some decent places for parts and such. I'm not sure where you are but I believe he's in the Nottingham vicinity.

Title: Re: 2002 Savage will not start
Post by don sinclair on 02/23/06 at 08:02:46

Guys ,
Don't really want to prolong this thread about my bike but altho it runs great now, it does not want to start when its warm. I'll take it out for a ride , shut it off and come back to start it ...it won't ....until it cools down. I've tried adjusting the mixture but so far the only thing that works for me is to let the bike cool down. Anyone else have this problem and how did you solve it .
Thanks again Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 02/23/06 at 16:22:50

Don,

A little more info would help.

Does the starter turn? Do you smell gas? Etc?

Steve

Title: Re: 2002 Savage will not start
Post by don sinclair on 02/24/06 at 21:30:44

Steve, Yes the starter turns and yes I do smell gas.
I'm thinking it may be set too rich (at the mixture screw) I'll try to close it down a 1/2 turn. Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 02/24/06 at 22:39:25

Don,

IIRC, all you did was the 1/2 spacer mod, right? That should only change the midrange throttle repsonse. But adjusting the idle is a reasonable thing to try.

Let us know if that solves the problem.

Steve

Title: Re: 2002 Savage will not start
Post by Dynobob on 02/25/06 at 06:46:48

don sinclair wrote:

Steve, Yes the starter turns and yes I do smell gas.
I'm thinking it may be set too rich (at the mixture screw) I'll try to close it down a 1/2 turn. Don

Are you twisting the throttle while trying to start it ? I never give my bike gas by twisting the throttle while starting. Works for me.

Title: Re: 2002 Savage will not start
Post by Don Steel on 02/26/06 at 09:10:43

Savage_Rob wrote:

Hi folks,

I'm in East Yorkshire, a place called Driffield half way in between Hull and York!

Title: Re: 2002 Savage will not start
Post by thumper 92105 on 02/26/06 at 20:18:13

i bet a lot of us thumper riders learned a lot from reading all the replies. my savage once didn't start after i gassed it up, i imediatly thought something was wrong with the gas but turned out i was pinching wires under the seat, it started when on the kick stand in neutral an me standing on the side but when i got on it died so remobed the seat moved the wires and went on my way. goes to show sometimes we jump to conclusions like me blaming the gas.

Title: Re: 2002 Savage will not start
Post by don sinclair on 02/27/06 at 12:12:50

Here's the latest on my Savage....I've tried almost every adjustment on the idle mixture...from totally closed off to 3 turns out...stilll won't start when it is warm !! In fact, when trying to start it will backfire so now I'm thinking timing or electrical issue. This has been very frustrating because I'd rather ride than wrench!! I still refuse to bring it to the dealer to fix at this point. Don

Title: Re: 2002 Savage will not start
Post by don sinclair on 02/27/06 at 12:22:30

Steve: I did the 1/2 spacer mod and installed 157 main jet ,but the Jardine muffler was already on it when I got it.

Dynobob: No, I'm not twisting the throttle when trying to start it.

Thumper: I will check to see if any pinched wires are under the seat... good idea thanks . Don

Title: Re: 2002 Savage will not start
Post by Steve530 on 02/27/06 at 14:39:37

Hey Don,

157 main. That's pretty big. I have a 155 and I'm thinking that's too rich.

While you're checking for pinched wires, check to make sure that all the connections are tight. Sometimes a bad connection is worse when hot.

Have you checked to be sure you're getting a spark when it's hot?

Title: Re: 2002 Savage will not start
Post by Jim_R on 02/27/06 at 17:25:17

I wonder if that 157 flooded and the plug! What size pilot jet do u have?

Title: Re: 2002 Savage will not start
Post by Dynobob on 02/27/06 at 19:41:43

It really sounds like something electrical. When a bad electrical component gets hot that's when it fails. Since you previously had starting problems, I think this may still be haunting you.

Electronics isn't my strong suit but I'm thinking maybe it's your coil that's failing. They sell freeze spray at electronics stores. Maybe a quick blast to your coil will tell you if it's a heat induced failure. If it instantly comes back to life you will have found your problem.

Any electronics people here ? Maybe you could read the manual on the ignition system and how to troubleshooting it.

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 02/28/06 at 05:15:50

I may have misunderstood but I didn't think it was stalling when warm; just that it wouldn't start back up after shutting it down until after it cooled. It almost sounds like flooding and just needing time to evaporate. A fouled plug could exacerbate that too, I guess. So ride it, park it, shut it down, try starting. If she won't start, drain the float bowl and retry.

Title: Re: 2002 Savage will not start
Post by Ed_L. on 02/28/06 at 06:46:52

It almost sounds like a vapor lock or pinched fuel line. I don't know if you changed the fuel line and vacumn line with everything you have already done to the bike. Could be the tubing leaks when hot, just a thought.

Title: Re: 2002 Savage will not start
Post by Reelthing on 02/28/06 at 07:04:23

157.5 is pretty big - but shouldn't effect startup much as long as the needle has it shut off like it should. - are you real sure the slide was very clean when reinstalled?

so does it keep running after it get's hot and just won't start again or does the engine die after it warms up?

Title: Re: 2002 Savage will not start
Post by don sinclair on 03/01/06 at 07:22:55

Jim_R: I have not changed the pilot jet so I assume that
it is stock size.

Savage_Rob: It did stall out twice when warm and also would not start until it cooled off.

Reelthing: Re: the slide..."was it very clean " I was very careful when I put it back together so I really think that the problem has to do with ignition or timing. Don

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 03/01/06 at 07:33:22

Okay then. Dynobob may be right. Try the freeze spray on your igniter, voltage regulator and coil and see if it makes any difference. I would doubt the coil would succumb to this sort of problem but it's certainly worth a shot.

You might also pull your vacuum line to be sure the petc0ck isn't allowing fuel into the vacuum line.

Oh yeah, it's worth checking to be sure the brass washer/spacer that was installed with the main jet is actually still there. It's been known to cause similar problems.

What have I done? (http://suzukisavage.com/cgi-bin/YaBB.pl?board=RubberSideDown;action=display;num=1123171986)

Title: Re: 2002 Savage will not start
Post by don sinclair on 03/03/06 at 10:41:45

Update ...after reading many related posts re "hard starting,carb issues, ect... I thought about what changes I've made.
To review, my bike ran fine( but slow) before I did anything to it. All I did was install bigger main jet ( it was a 155 not a 157 as I recently said),sanded spacer to about 1/2,and adjusted mixture screw(pilot) and put in a new battery and spark plug.
It ran great for a while, then started to quit when it got hot.
That's where I am still. I do remember tho that before I put the diaphragm assembly back in after mods to the white spacer, I "cleaned" the slide surface with wd 40 and applied a small amount of light grease to the "piston",thinking the some lube would be a good thing..Now I'm thinking that may be the source of my problem!!. Unfortunately,when I reinstalled the cover , I stripped one the internal threads on the carb top .(I was hoping that I would never have to take the top off again !!
What do you suggest ? Thanks Don

Title: Re: 2002 Savage will not start
Post by Reelthing on 03/03/06 at 10:57:49

Grease on the slide just will not work -even greasey/dirty finger prints are not good and
can cause the exact problem you describe.

How do I know? was he born with this knowledge :D
yea I wish - I've cause it on this carb and a couple of others when I put them back together in a hurry. If it's just a little bit what you'll see when you take the slide out is all the grease has collected at the bottom of the bore forming a ring - as the carb get's hotter the tolerences shrink as the metal expands - you need to clean out the bore and clean the slide - I use a little spray electric contact cleaner on a rag.

Title: Re: 2002 Savage will not start
Post by Dynobob on 03/03/06 at 11:30:39

don sinclair wrote:

I "cleaned" the slide surface with wd 40 and applied a small amount of light grease to the "piston",thinking the some lube would be a good thing..Now I'm thinking that may be the source of my problem!!.

I think you have it figured out Don. No grease should be on the slide. You may be able to spray some carb cleaner in from the top or from the rear to clean it up.

I'd do something about that stripped screw. Either put a helicoil in it or see if a nut will fit on the bottom.

Personally, I'd remove the carb :'( ,clean the slide, and have the stripped threads helicoiled by a machine shop (or do it yourself).

Title: Re: 2002 Savage will not start
Post by don sinclair on 03/03/06 at 20:15:52

Thanks guys..I'm going to take the carb off(again).
Should I use electric contact cleaner or carb cleaner on the slide and cylinder?
Yes , I'm going to have a machine shop do the rethread.
Thanks again, don

Title: Re: 2002 Savage will not start
Post by Reelthing on 03/03/06 at 20:49:30

either one should do the job - I just have the contact spray around for use on pc boards - cleans well, doesn't hurt plastic or leave any residue

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/24/06 at 14:22:24

Been a while but here's the latest. Since the last post a couple a months ago , I purchased another bike which I've been riding but need to get the thumper reliable so I can sell it.
Anyway, I did carefully clean the slide and put carb back together, but still have the SAME problem ....it start and runs fine for a few minutes(after it warms up then pops, farts and dies.
I pulled the plug and it looks normal( not wet) maybe a little dry. The petcock seems to work fine .Now I'm thinking that it's not getting enough gas. When i pulled the carb to do the mods, I never touched the pilot jet . Could a clogged pilot cause this to happen? Any other suggestions ? Thanks Don

Title: Re: 2002 Savage will not start
Post by Trippah on 04/24/06 at 15:49:12

Don- what is your new ride? Inquiring minds and all that. Sorry thumper missed the boat for you, but after a while it can get aggrivating. By any change, did you go Guzzi. (I was thinking a 750 breva would be a good replacement ride). I kinda cringed when you mentioned WD-40, I think it turns to gum after awhile. frankly I think I'd send the carb to someone or sell as is- and let the next lucky owner know the problem and let them fix it. They might enjoy the challange :D

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/24/06 at 16:10:19

Hi Trippa,
Always liked old Guzzi's so I bought a 1976 Convert
model. I'ts a kick ... a 1000cc ( with an auto trans)actually
a 2 speed auto.Goes up to 60 or so in low gear ! But it's a heavy bike to push around. No such thing as a "perfect bike"
Back to the Savage...I really need to get it running right cause I just can't take the major "hit" I would have to take to sell it as is. I paid $2500 for it . I'd probably get less than $1500 for it as is. Just cannot afford to take that kind of loss.
So guys , I still welcome any help on this. I really think this problem can be solved without giving my dealer $75 an hour
just for labor...but I just might have to do that.It kinda goes against my "cheapskate" personality .)

Title: Re: 2002 Savage will not start
Post by necropsy on 04/24/06 at 17:38:13

Sticking float and/or needle?
Sounds like the bowl maybe running dry.
As soon as it dies, try unscrewing the bowl drain and see if it's dry, or if/how much gas drains.

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/24/06 at 22:23:28

The bowl isn't dry ,but it was down about 1/2 an inch.
Is it practical to unscrew the pilot jet from underneath or do I need to
take the carb off(for the 5th time!) Don

Title: Re: 2002 Savage will not start
Post by lancer on 04/25/06 at 00:48:42

You can get the pilot out from the bottom, but frankly, with the problems you have had I would remove the carb and completely disassemble it, clean everything, blow out the passages, inspect each part to ensure it is good, and then reassemble it.

If it is clean and the parts are good, and you put it together correctly...it will work.

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/25/06 at 07:14:14

Thanks Lancer, I'll take it down again and do a total cleaning like I should have done the first time. Don

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/25/06 at 13:15:19

When doing the carb cleaning, is it necessary to remove the choke assembly ?

Title: Re: 2002 Savage will not start
Post by woodworker on 04/25/06 at 13:33:48

don sinclair wrote:

When doing the carb cleaning, is it necessary to remove the choke assembly ?

No, it is not necessary to remove the choke assembly.
When you completely disassemble the carb, remove all jets and blow out all passages etc. you should also put the diaphragm/slide assembly up to a light source and carefully check the diaphragm for any holes or cracks.

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/30/06 at 11:38:26

Ok Guys, Today I've pulled carb down and am in process of the cleaning... however , I just measured the float level and its 1 1/4 inches from bottom of float(when turned upside down) to the edge of the carb body. I could not find specs on what this measurement should be. My bike is a 2002 model .
Does anyone have this measurement ( hopefully in inches)
Thanks again . Don

Title: Re: 2002 Savage will not start
Post by stock87 on 04/30/06 at 16:48:30

Is there any rust in the tank? did u take the Petcock out and clean it, check to see if the screen is clogged.

Title: Re: 2002 Savage will not start
Post by don sinclair on 04/30/06 at 19:34:11

Good idea, Yes I will take petcock down now as well as check it out.
Again tho, does anyone have the proper setting for the float bowl ?
If it is 1" or less then I think that means that gas may not fill my bowl and cause bike to stall from not getting gas.

I am NOT giving up on this issue ,YET. Thanks Don

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/07/06 at 22:09:58

My LAST rebuild
I took the carb down( for the 4 th time), soaked with carb cleaner, removed jets
and blew out everything with compressed air , rechecked the float level and put eveything back together. SAME story,bike runs fine UNTIL it gets warm, then shuts down.
I decided to take it to the dealer to fix.
Since I've checked everything EXCEPT electrical. I'm hoping they find the solution. I'll let all of you know what they do. Don

Title: Re: 2002 Savage will not start
Post by babbalou on 05/08/06 at 02:57:45

don sinclair wrote:

My Clymer manual says the float level should be 1.06" to 1.114 " (metric; 26.95mm to 28.95mm)

Title: Re: 2002 Savage will not start
Post by Mike M on 05/08/06 at 12:23:15

Don - this has been mentioned several times through the thread, but it still isn't clear to me....Is the vacuum line to the petthingy properly attached and not leaking? Have you tried to run with the PRI setting? If you problem goes away in PRI, the something is wrong with that vacuum line. I knock mine off or damage it everytime I remove the tank because I either forget to detach it in the first place, or fail to reattach it.

Title: Re: 2002 Savage will not start
Post by SeattleSavage on 05/08/06 at 22:48:17

Hmmm sometimes when the electronics get hot they do loose power. If your coil were failing you could get a weak spark after running her for awhile. Check it for cracks or pull the plug wire attach a second plug and check to see if it has a spark. (when it's hot)

Just another suggestion, the thread is the longest I've seen, so I didn't want to be left out.
Good Luck with it Don, I know how frustrating it can sometimes be.

Kevin

Title: Re: 2002 Savage will not start
Post by stock87 on 05/09/06 at 05:12:19

YO DON WHATS GOING ON? ANY WORD FROM THE DEALER?

Title: Re: 2002 Savage will not start
Post by serowbot on 05/14/06 at 00:03:22

Don,
I'm having a a very similar problem. Have tried jetting, carb, spark, blah... blah...
After reading about pet-thingy and pet-thingy conversion I'm leaning toward conversion.
Some posts say p-t goes bad and leaks into crankcase, some say p-t goes bad and sucks fuel into mix, bypassing pilot.
Ding! Ding! Bells are going off in my head!
I'm rich at idle even with mix screw full in. Stumbly idle, worse when warm. Hard starting. Bad milage.
I think I might have gas in the pet-thingy vac line feeding into the idle-mix.
Mike M may be on the right track.
Hope it helps us both.
Not alone in this nightmare, Bob

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/15/06 at 13:09:24

First of all.. to Stock87 and others, I was extremely busy
last week ,didn't touch the Savage. It IS going to the dealer
Tues( tommorow).
To Mike M, Vac line to carb is properly attached,no leaks.
Yes,I tried have running it in PRI... motor still stops whenit gets hot.
To SeattleSavage, spark DOES seem weak when bike gets hot so I think maybe it is heat /electrically related. I no nothing about electrical so I hope the shop can finally solve the problem. Don

Title: Re: 2002 Savage will not start
Post by Savage_Rob on 05/16/06 at 05:45:24

You could use clear tubing on the vacuum line to see if it's getting fuel in it... and either a clear line or clear filter on the fuel line to see when it has fuel. If you suspect you may be getting excess fuel dumped into the carb, whether through the fuel or vacuum line, please check your crankcase oil to be sure it hasn't been contaminated. If you think it may have been but aren't sure, it's definitely safer to change it.

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/19/06 at 12:19:40

HELP GUYS!!!
The dealer just called me and said that the cd coil is not working properly and is saying that I need to get a new stator also since the coil cannot be replaced separately on my model(2001).IS THIS TRUE? He says that parts and labor will be in the $500 dollar range!!!
I told him NOT to do anything yet. I want to check this out further. What would you do ? Thanks Don

Title: Re: 2002 Savage will not start
Post by Dynobob on 05/19/06 at 12:30:24

I looked it up at bikebandit.com and it's available seperately. $69. Perhaps you misunderstood the dealer ???

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/19/06 at 12:34:10

By the way ,he said the stator checks out ok. What the deal?
I know nothing about electronics. Don

Title: Re: 2002 Savage will not start
Post by Dynobob on 05/19/06 at 12:46:17

Here's the page. There's other parts in the $400 range.

Link (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view~schem_dept_id~710783~section_dept_id~1~section_dept_name~OEM+%28Stock%29+Parts~dept_type_id~2~model_dept_year~2001~model_dept_mfr~Suzuki~model_dept_id~703429~model_dept_name~LS650PK1+SAVAGE.asp)

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/19/06 at 12:59:45

Dynobob,
Thanks , I got to go back to work soon. I'll try to make sure I write down exactly what the dealer says to me by phone later today. Don

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/20/06 at 12:35:14

Here's what my local mc shop said .
He says that the stator itself is ok but the "pulse generator"
is shutting down( see page 212 of Clymer manual-part number 2 on the diagram). He described it as a kind of magnetic switch. He says that part is all part of the stator assembly and is not available separately.
The big issue as far as I know is that the Clymer book he is using is for 1986-1988 Savages ! My bike says "2000" on the
front fork id plate.
Does anyone know the differences in these years regarding these parts?? For example would the older year parts fit if they are easier to get ?
The bike bandit site parts don't look like Clymer info at all!

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/20/06 at 12:58:41

UPDATE.... I just found the Ron Ayers website.
Went to "Magneto" and there was the stator assembly with that part attached but no separate part # so maybe he's right .... I need to get the whole darn thing ! They quote $241.79 but also may be a discontinued part ... What gives ?
What are my chances of finding good one used?
I'm thinking maybe I should get the part and install the stator my self and save his $65 an hour labor charge . He says about a 2 1/2 hour job. Anyone here changed one out ? Don

Title: Re: 2002 Savage will not start
Post by Dynobob on 05/20/06 at 16:37:03

You've confused me on the year but the stators are the same from 1988 to 2002. I compared the pictures at Ronayers and Bikebandit and they're identical.

I do see the part he's referring to. It's the electronic ignition pickup and he is right - it's part of the stator assembly.

That part was changed for the 2003 model year (according to bikebandit).

Bikebandit shows it as available. Ronayers shows it as discontinued. I don't understand this because Suzuki is mandated to keep parts for 10 years by the government I think.

I'll let someone else advise you as to the difficulty of replacing it yourself. If you go that route, you'll probably be charged the labor your mechanic used to diagnose the problem + towing or whatever. You might also p!ss off your mechanic a bit ;)

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/22/06 at 09:35:29

Has anyone on this list ever changed out their stator assembly( AKA magneto) ?Is so, does it involve partial removal of the motor? thanks don

Title: Re: 2002 Savage will not start
Post by Bd on 05/22/06 at 11:12:09

I would just pay the dealer and move on

Title: Re: 2002 Savage will not start
Post by don sinclair on 05/22/06 at 12:40:44

Bd , You are right .Its time to end my do it yourself bs at this point. Thanks don

Title: Re: 2002 Savage will not start
Post by Kropatchek on 05/23/06 at 07:29:22

don sinclair wrote:

Has anyone on this list ever changed out their stator assembly( AKA magneto) ?Is so, does it involve partial removal of the motor? thanks don

You don't have to remove the motor.
Remove the magneto cover and undo the bolts that hold the stator.
The ignition pick-up is a separate unit and can be replaced on its own. You have to make an oiltight seal yourself as you will have to separate the cable loom.

Greetz
Kropatchek 8)

Title: Re: 2002 Savage will not start
Post by don sinclair on 06/21/06 at 22:27:48

Final Chapter... Got the Savage back last week and it runs great. It WAS the Stator assembly. After parting with $551.00 to the shop , I've decided to sell the bike.... a 2001 light blue Savage with 8k miles on it. Its got the harley style windshield and afermarket highway chrome pegs. It also has a rejetted carb and 1/2 wht spacer mod and Jardine muffler. Also included is the stock muffler. Most important ,the bike no longer has the annoying BACKFIRE problem.Price 2800.Thanks to everyone who helped me solve my issues with the Savage.I'm in Oceanside Ca 760-525-4122 don