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Message started by Cass on 05/05/15 at 18:37:44

Title: New rider, 2001 s40 not running well
Post by Cass on 05/05/15 at 18:37:44

Hi all, first time posting. I bought a 2001 s40 about a month ago. It had approximately 2,500 miles on it. Thanks to these forums, I made saddle bag supports and moved my rear turn signals to the license plate all with stuff I found at Home Depot. Saved myself about $100, so thanks for that! (want to see pictures?) The previous owner said that it had sat in the garage for the past year. It was idling high and running rich. I took it to a dealer with certified Suzuki mechanics and had them give it a good once over and give it a tune up. Everything's stock from what I can tell.

Here's what they did: Changed oil and filter, changed spark plug, replaced float gasket, replaced needle valve assembly, replaced pilot jet, replaced needle o ring (from parts invoice). Their notes narrative say "Cleaned carb replaced float valve, properly set float height. Set drive belt tension, tire pressures, etc. Attempted to tune out backfire. Some backfire on decel is common with this model. Bike has had carb work done before."

So when I got it back, I was excited that it ran like a whole different machine! Then after riding it for a few weeks, I've started to become rather discouraged.

It seems to be running out of gas too soon. For example, today at work I had to put it on reserve to get it started. I went to the nearest gas station to fill up, and she only took 1.55 gallons. That means there was 1.25 left in the tank. Reserve is supposed to be .6 gallons, right?

It hates to start up in the morning. I'm talking May in San Diego mornings, like 60 deg F, maybe 55 at the lowest. The "choke" does nothing for me. In fact, if the bike is running and then I pull the knob (even the slightest bit), it kills the engine. So, without the choke, it'll start up, but then stall after 30-60 seconds. I have to stand there holding the throttle open a bit for several minutes before I can let go or it just stalls again. Some times I just jump on and ride, restarting it at stop signs along the way to the highway. Seems nice and warm by the time I get there. I marked the idle adjustment screw so I knew where the mechanic had it set. Then I turned it up about 3/8 of a turn. That was great in the afternoon when it was warmer out. Next morning, 55 degrees, the whole stalling routine again.

Today leaving work in reserve, after filling up and switching back to "FUEL" from "RES" it stalled on me before I left the gas station parking lot.

I've read about the Raptor petcock and the white spacer mod. I'm a mechanic (I work on H-60 helicopters for the Navy) but have never done carburetor work or motorcycle work.

Open to any and all suggestions! Thanks in advance - Cass

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 18:42:19

Go to the tech section and find a thread called "Test your petcock" or something like that. The stock piece is junk.

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 18:43:42

Ok, I did the leg work for you. ;D

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1251932429/1

Title: Re: New rider, 2001 s40 not running well
Post by Cass on 05/05/15 at 18:45:59

I already have that one bookmarked ;-)

Do you think that all of my problems are coming from there?

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 18:48:26

There is no fuel pump so if you have 1.5 gallons left, it should run. The petcock is probably the culprit.

Do you know what size jets the dealer installed?

Title: Re: New rider, 2001 s40 not running well
Post by Cass on 05/05/15 at 18:59:40

Searched the pilot jet part number on Google, says it's a 52.5.

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 19:04:38

That's the stock size.

Title: Re: New rider, 2001 s40 not running well
Post by justin_o_guy2 on 05/05/15 at 19:09:43

Congratulations on all that you've accomplished!
Don't get discouraged,bikes aren't cars, they demand attention and knowledge. You hang out here, this bunch can talk you through the little things that are frustrating you. Those Certified Suzuki Mechanics have completely destroyed at least 2engines by installing the oil filter bakkerds.

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 19:11:10

If it were mine, I'd leave the dealer alone and read threads on this site pertaining to the inner workings of this carb. It's a very simple carb. If you can work on a helicopter, you can open up this carb. Clean everything thoroughly and make sure your jets are at least stock and the dealer didn't install huge jets or something. It will at least be a base you can start from.

Title: Re: New rider, 2001 s40 not running well
Post by Art Webb on 05/05/15 at 19:35:23

Do the Raptor, or at least test the Petty
I SUSPECTED mine was bad and just did the swap and never looked back
it's not a matter of IF the factory petty will fail, it's a matter of WHEN
My peace of mind is worth $30 and 10 minutes work

Title: Re: New rider, 2001 s40 not running well
Post by Flint on 05/05/15 at 19:39:55

I have a brand new S40. Some of the issues I found were...

1 Belt way too tight

2 When I did the valve clearance check the spark plug was finger tight. Valve clearance was good.

3 The bike, at times, seemed to run out of power other times it had lots. I put a Raptor petcock on and seems to run fine all the time.

I suspect your petcock is faulty. My bike only has 2400 miles.

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 19:48:27

Suzuki didn't spend billions of dollars R&D'ing this bike. In fact, I think the official dollar figure is around $15.26. It's their bargain basement cruiser. The stock petcock is junk. Even if it turns out to not be the problem, get rid of it and get yourself a Raptor.

Yamaha p/n: 5LP-24500-01-00

Beware of cheap Chinese Ebay impersonations. If it doesn't have the Yamaha logo and p/n then pass on it.

Title: Re: New rider, 2001 s40 not running well
Post by Cass on 05/05/15 at 19:53:26

Thanks everyone, looks like as I anticipated, I'll be going with a Raptor petcock. I'll make sure to get the real deal and not a knock-off. Now here's another question: should I drive the cage until I get the petcock swapped? I'm ordering it tonight, but I don't want to do any damage. Oh, and when I put the line into the gas can and switch to PRIME, is that going to drain the whole tank out? Don't want to try using too small of a vessel...

Title: Re: New rider, 2001 s40 not running well
Post by Flint on 05/05/15 at 19:56:42

Amazon has the real Raptor petcock for $26.

Title: Re: New rider, 2001 s40 not running well
Post by Kris01 on 05/05/15 at 19:57:38

Prime will drain the entire tank.

You can't hurt the bike by running it with a faulty petcock. It just may not run. You decide. ;)

Title: Re: New rider, 2001 s40 not running well
Post by Art Webb on 05/05/15 at 20:05:17

You can ride it on Prime until you get your Raptor, I did (only way it would run, didn't have a car, either ;D )

Title: Re: New rider, 2001 s40 not running well
Post by justin_o_guy2 on 05/05/15 at 20:10:36

5D5C475F5A5B030107330 wrote:

The tank will drip, no matter. But Prime will rid the tank of almost all gas.
You know to be ready for some minor fuel, not done near the gas water heater...
I bought mine from the local dealer. Keeping that money local, I try to support the local businesses.

Title: Re: New rider, 2001 s40 not running well
Post by Flint on 05/05/15 at 20:14:25

Get all you tools ect. ready and take the tank off and lay it on the side. I changed mine in about 3 minutes after the tank was off and every thing ready. Maybe lost 1 cup of gas.

Title: Re: New rider, 2001 s40 not running well
Post by justin_o_guy2 on 05/05/15 at 20:19:48

I didn't pull the tank. And wouldn't. It's a hassle and the speedometer cable requires planning. Don't wanna lose the o ring. Much easier to leave it secured, in my biased opinion.

Title: Re: New rider, 2001 s40 not running well
Post by old.indian on 05/05/15 at 20:33:58

Cass: It definitely sounds like you need to replace the petcock. Order one from the supplier recommended on this site. (I ordered one on Amazon and they sent the wrong one... >:() If you are going to work on the carb remember to reassemble in the same way it was. (I had to re do my carb when I put one spring ABOVE the diaphragm instead of below it.) ::) Other than that..... They used to have areas around the bases' motor pool where you could take you vehicle to work on, and usually there would be some gearheads around that would help and/or advise...

Title: Re: New rider, 2001 s40 not running well
Post by jcstokes on 05/05/15 at 21:00:37

Don't disassemble the carburettor until you have read some of the threads about stripping screws, some are assembled with studlock/threadlock or something.

Title: Re: New rider, 2001 s40 not running well
Post by Cass on 05/05/15 at 21:45:36

I would much rather not pull the tank, obviously. Seems like an unnecessary procedure based on the petcock thread in the tech section. I am fortunate enough to work with some darn fine mechanics with skills on 2 wheelers as well as rotary wingers. I'll do the petcock over the weekend provided it gets here by then. Hopefully that alone will do the trick. I am very much looking forward to finding out that it does. Thanks for all of your input. I love this forum!

Title: Re: New rider, 2001 s40 not running well
Post by gizzo on 05/05/15 at 22:06:10

The fact the mechanic adjusted the float height rings alarm bells,just because I don't trust bike mechanics abilities. When I got my savage It ran a bit rough,float was too high. Dropped it a bit for an improvement. Maybe check the mystery pipes out the carb body aren't blocked. They vent to atmosphere,if they're blocked fuel can't get in. (because the air can't get out ). But first I'd do as the others suggest,check the fuel tap. I'd check the belt tension as well, using the specs in the tech section. Others say the Suzuki spec is too tight.