SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> 2006 S 40 Sputtering at WOT.. HELP.... /cgi-bin/YaBB.pl?num=1377988844 Message started by s40guy on 08/31/13 at 15:40:44

Title: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 08/31/13 at 15:40:44 :-[I have a 2006 S40 Bike I bought used. At about 45-50 mph with throttle wide open it sputters and hesitates like it is trying to get power but cannot. The front band between the carb and the cylinder was loose so I tightened that and it did not help. The bike did have some old gas I n the tank because it smelled old so I put in sea foam with a full tank of fresh gas on top of the old. When you ease the throttle, it will get up to 65 MPH with no problem. it is only on full throttle that I get the sputtering. Also it will back fire a couple times coming back down from WOT. Any suggestions or ideas? Could it just be that I need to run a couple of tanks of fuel with sea foam to clean out the carb? Side note when I get the sputtering and pull out the choke as a test, the engine does not change at all. maybe the choke might be messed up? Any advise would be helpful. I am very disgruntled with the S40. Please help. Thank you. S40 Guy.. :'(

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by jcstokes on 08/31/13 at 15:45:57 Turn the petcock to prime and see if it runs better.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 08/31/13 at 15:49:19 OK. If I try that and it works what will that tell me? I put in a new standard NGK plug so it has a new plug in there. Any help would be great. I am frustrated. I will try the prime. And re post the results. Thank you. S40 Guy.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 08/31/13 at 16:04:19 I just tried running it on Prime. Same results. Do Throttle wide open and at about 45-50 mph, sputter and spits. Ease the throttle using about 1/2 to 3/4 and it runs just fine . No spit or sputter. Help I am totally confused on what the issue could be. Thanks, S40 Guy..

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by verslagen1 on 08/31/13 at 16:47:42 I'd do a thorough cleaning 1st

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by jcstokes on 08/31/13 at 16:48:27 First try tapping the float bowl with a screw driver handle. Then if that doesn't help go to the tech section of this site, click on table of contents and scroll to petcock, you will find a lot of useful info there before you pull things to bits.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by Serowbot on 08/31/13 at 17:29:59 Check yer' air filter, too...

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 08/31/13 at 17:58:53 Do you think allowing the sea foam time to run through will do a decent enough job of cleaning, or do you think I will have to disassemble the carb for cleaning? I will try the tapping on the float bowl tomorrow. The air cleaner was good. I just cleaned that when I bought it and it appears really clean. I also saw a post on testing the petcock. What confuses me is everything is fine at 1/2 to 3/4 throttle. No spit, sputter, etc. Only on WOT do I have the issue. I really hate to take the carb off to clean, I was hoping for Sea Foam to clean it pretty decent. My other bikes I owned I used the Sea Foam the first couple of tanks to clean. I have never had this issue with the Open throttle spit and sputter before. That is where I am lost. S40 Guy.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by Steve H on 08/31/13 at 20:20:10 Sounds like a fuel delivery issue to me.  WOT requires a lot more fuel than half or 3/4 does. Could be a coil breaking down at high speed.  But, if it'll run the same RPM slowly going to 1/2 or 3/4 it rules that out and puts it back to fuel delivery.  Sounds like you're running out of gas. Don't know what kind of mods if any are on the bike.  It might be that you have to rejet for something that has been done to the bike.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by justin_o_guy2 on 08/31/13 at 22:05:18 How ;long has it been doingthis? Since ya got it? Howmany miles you got on it? How many miles on the bike, total? Drain the carb bowl & see what it lookslike.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 09/01/13 at 06:12:27 Been doing it since I first rode the bike. When I test drove I was in a parking lot so I only could use low throttle. There are little less than 7,400 miles on it. it was outside most of the time with a cover on it in Indiana, and during the winter it was in a garage. To the best I can see no mods were done to it. I did drain the carb and the fuel looked very clean. No debris. I was surprised. nothing bad at all in the clear container I used. Gas did smell a little stale. it had about a quarter of a tank when I bought it. I filled it up with my lawn mower gas (mid grade Phillips 66) and I had to wait to get two tires and fork seals done on the bike before I could test drive for real. Friday was my first day and it started the sputtering right away on WOT ONLY!. Yesterday I have the same results but not sure if it improved slightly or not. Around 45-50 mph is when you get buck city on WOT. I changed the oil to Spectra 10w 40 Semi Synthetic (same I used in my Yamaha Virago) when I got it, Changed oil filter, Put in new spark plug, and a new fuel cap as the one that was with the bike had the key broken off inside of it. Around the top portion of the tank there is a little rust near the top, but inside the bottom lip of the fuel tank it is clear as the rest also looked clear, so I assume the rust is only at the top portion of the tank. No rust flake, just the rust when you wipe a rag or paper towel on it to clear it up. Other than the WOT issue, and the occasional back fire (which I think it from the same WOT issue) the bike runs great. No cam noise yet but I am keeping an eye on it. Hoping for at least 12,000 miles or more before I have to get with Versay on a tensioner. I have 3.5 oz. of Sea Foam in the tank yesterday to run it through to help clean up things in the carb. I am an average mechanic with very strong electrical skills and average carb type skills. When I replaced the spark plug I did lose the speedometer O ring but got two new ones from Bike Bandit with the help form you guys here. No where does it tell you (owners manual or Cylmer manual 1986-2012 edition to watch out for this little guy to fall out. never even mentions this little guy. Any advise or help would be appreciated. Thank you for your help. S40 Guy.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by Charon - FSO on 09/01/13 at 06:33:51 Test fuel delivery to the carburetor. Remove the fuel line from the carb and point it to some suitable collection container. With the petcock ON or REServe there should be no fuel flow. Turn it to PRIme and observe fuel flow. If it isn't adequate (somewhere around a pint per minute, I think) there is a problem in the tank, petcock, or the screen on the standpipe of the petcock. If the flow is adequate, put the fuel line back on the carburetor and open the drain screw on the bottom of the float bowl. Fuel flow will be slower, because it has to go through the float needle valve, but there should be good flow. If not, there is a filter inside the carburetor above the float needle seat. Personally, I have no faith whatever in the magical restorative powers of Seafoam. I think the gasoline (and probably the ethanol in it) are better solvents than Seafoam could ever hope to be.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by WD on 09/01/13 at 08:22:40 It's a vacuum operated slide carburetor. You won't have instant response like we had on real versions with either a cable operated slide or a butterfly plate. And keep in mind, these bikes at lower elevations desperately need a larger main jet. Go up 1 size on the main jet, should alleviate the worst of the stumbling. You're trying to get Porsche 911 Carrera throttle response out of a VW Beetle... in stock form, it doesn't happen.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by justin_o_guy2 on 09/01/13 at 10:55:34 Id pull the air tube to the carb from the air filter & check the slide for EEEEze of motion,, Make sure the vacuum that operates the slide is getting to it. A leak (small one) may not affect it much at low RPM, If its an RPM thing, WOT in any gear, thats a clue.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by Charon - FSO on 09/01/13 at 12:52:11 Rereading the original post - This bike does not have a choke. It has an enrichener. Unlike a true choke, the enrichener does not work if the throttle is much above idle, so you can't really expect much change if you pull it out with a wide-open throttle. Many of us seem to confuse WOT and high rpm. They are not the same, and in many ways are independent of each other. The original post describes a sputtering and hesitation with WOT, but at only mid range on RPM (45 - 50 mph). With part throttle the bike runs up to 65 mph. This could point to either a fuel delivery problem, where fuel flow is inadequate to support WOT demand, or to an ignition problem where WOT causes high cylinder compression pressures and something in the ignition is breaking down and not delivering spark. I would suggest checking the fuel flow first, partly because of the description of old gas and partly because it is easy to do with the bike stopped.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 09/01/13 at 13:45:03 Yes, I can get the bike to accelerate up to 65 if I use the throttle slowly and ease it up to about 1/2 to 3/4. Slightly above 3/4 is where I get the sputtering. When you have the throttle wide open from say 35 mph or less, it will go up to about 45-50 before it starts sputtering when you still have the throttle open. It cause the bike to shake and hesitate like you are running out of gas. Backing the throttle off until about 3/4 or less cause the motor to even out and you can then increase the speed to about 65. I don't wan to get a ticket so that is why I back off after 65. I believe it is a fuel issue but have done the tests that other s have listed, vacuum hose, primer, etc., and still the same. I did put in the Sea foam and about an ounce of Gum out Carb cleaner. It seems a little better but the sputtering and bucking like you are running out of gas is still there. I am think maybe I need to take the carb off and do a cleaning like Versay suggested. Maybe then I can se what is going on. Seems like I am getting fuel from the tank, and no gas is in the vacuum line so I am not sure what else to do other then take the carb out. If anyone has any other suggestions please let me know. I will let everyone know how I make out the my ordeal. Thank you. S40 Guy.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by verslagen1 on 09/01/13 at 14:49:00 you said you blew the jets out... what sizes were they?

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 09/02/13 at 03:41:02 Vers, I didn't blow out the jets. I did not take the carb off yet. I cleaned up everything around the carb, tightened the ban that was loose that connected the carb to the cylinder, checked the vacuum line from the petcock to the carb and no fuel was in it, ran with prime and no change. I had not removed the carb yet. Everything on the bike should be stock as the person before me said the only thing he did was oil change, and looked like he put a battery in it. The batter was a maintenance free but was too large and I replaced that battery with the correct one so I could get the cover back on the Tool box holder. The sputtering when it happens keeps you at the mph you are at. It will sputter and spit for a long time and you can't go any faster. back the throttle off until about less than 3/4 and she takes off just fine. Maybe that is the way it is supposed to work on the S40, I don't know. When I do take the carb off how do I know what size the jets are? Do I have to replace the float bowl gasket? if I do I need to get one before I take it off. Thank you for your help. S40 Guy.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by WD on 09/02/13 at 06:08:33 Gasket is infinitely reusable, just don't get any carb cleaner on it. Torch tip cleaners are your best friend for dirty jets. Jet size should be stamped on the face of the jet, or the side.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by verslagen1 on 09/02/13 at 08:12:29 I think it's time for you to open it up and take a peek. one note of caution, if it's the 1st time, those screws will be a bear to get out.  Put penetration oil on the threads and use a small impact wrench.  Support the backside of the boss or you'll break right off. last ditch effort use a vice grip on the head of the screw.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by Grayowl on 09/02/13 at 09:27:36 Do you have an in-line add on fuel filter ?  My bike had very similar sounding issues when I was trying to run an extra in-line filter with the stock petcock.  Once I switched to the Raptor I could run the in-line without any fuel starvation issues.  There was a big thread about my filter issues about 8 months ago on this site.  In my case I still do not fully understand why the stock petcock has issues with an add on in-line filter, I feel it has something to do with air lock in the fuel line and stock petcock does not allow it back into the tank where the Raptor just lets it go through.

Title: Re: 2006 S 40 Sputtering at WOT.. HELP.... Post by s40guy on 09/02/13 at 16:17:20 :)Well put about 200 miles on her today and she is much better than yesterday. I can get 3/4 and a little bit more before the sputtering starts so I think I can live with that for now. Still have occasional back fire on decelerating, but again I can live with that. Most Harleys that go by are LOUDER!! than my back fire. I got this bike used to try it out to see if I would like it. So far I really like the S40. I think when this one comes time for major repairs I would look at a brand new one of these guys. so far I have owned a 2006 Kawasaki 125 eliminator (First bike after about 25 or more years of riding absence), A 2006 Suzuki GZ250, A 1995 Kawasaki Vulcan 750, a 1999 Yamaha Virago 535, and now my 2006 S40. My wife rides a Honda PCX150 Scooter and the Virago was the last bike we got for us riding two up on. Now that she rides the scooter, I wanted to go down in size to a smaller bike. yes, I know the S40 is a 3650, but the size, seat, handlebars, and overall feel of the bike feels smaller to me than my Virago. I considered an S40 or a Yamaha Virago 250, and found this one up for sale so we bought it. Even with the Throttle issue that is now livable, I still like it better than my other bikes. Not sure if the Gumout or the Sea foam, or just plain good gas running through took care of the carb issues or what it was, but I have ridden it today and had no problems at all going from 0- 60 mph fairly quickly, nor passing when I had to. Thanks to everyone who helped me out. If I was younger I think OI would tackle to get it near perfect. But at my age, I would rather ride and enjoy rather than keep fixing. Thanks again guys and I will keep you posted on how thing go. Take Care. S40 Guy.

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