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General Category >> Rubber Side Down! >> Dyna swap- Now FLAMES
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Message started by BeeBux on 09/18/23 at 14:57:14

Title: Dyna swap- Now FLAMES
Post by BeeBux on 09/18/23 at 14:57:14

I recently replaced the stock muffler with a Dyna and did a carb rejet (52/58, 145/150, 2 washers). Bike runs great and sounds amazing, but there are 6” whispy flames emitting from my muffler when I’m idling and I assume all through the range although I can’t see when moving. Too rich? Too lean? Something else altogether? I got them to go away turning the mix screw in to about 1/2 turn out, but after another 10 miles they were back when I arrived at my destination.

Title: Re: Dyna swap- Now FLAMES
Post by ohiomoto on 09/18/23 at 16:51:46

A 58 pilot and 2 washer is way too rich IMO (unless you are ~3k feet below sea level).

You really shouldn't need more than a 50.

Title: Re: Dyna swap- Now FLAMES
Post by Yoshi on 09/18/23 at 22:34:44

Flames are usually do to air leaks of the muffler

Title: Re: Dyna swap- Now FLAMES
Post by Dave on 09/19/23 at 04:21:42

The flames are all the unburned fuel that is coming out your exhaust.

My "go to" jetting for the first round is a #150 main and a #50 pilot.....and three machine screw washers on the needle. I have only had 1 bike that wanted a #52.5 pilot.....I have never had to install a main jet larger than #150 with a stock air cleaner.

A bike that is too rich will run OK - but is giving up a ton of performance.

What kind of air cleaner are you running?
At what elevation are you riding?

Title: Re: Dyna swap- Now FLAMES
Post by BeeBux on 09/19/23 at 07:39:14

I got a jet kit for this specific mod from a company called 6 Sigma, supposedly guaranteed to be correct for my specific machine. I installed a HiFlow air filter in the stock air box. I live at sea level. The stock jet was already 52.5 unless someone prior to me changed it, main jet is now 150 from 145.

Yoshi- I did notice a leak in the adapter I put on the header/muffler transition, as you said this might explain the flames in the muffler while the engine performs nicely. Gonna have that welded and see if overheating muffler goes away before trying to rejet.

Would y’all recommend going back to the stock 52.5 pilot and/or removing a washer? IS the 52.5 the stock pilot for a 2002?

Title: Re: Dyna swap- Now FLAMES
Post by Dave on 09/19/23 at 15:36:26

79796E636F72750B0B0A0F3B0 wrote:

Would y’all recommend going back to the stock 52.5 pilot and/or removing a washer? IS the 52.5 the stock pilot for a 2002?

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1098869040

Title: Re: Dyna swap- Now FLAMES
Post by zipidachimp on 09/19/23 at 22:22:15

Spent the last 2 years riding around with a 152.5, felt pretty lively. Took the exhaust off last winter and found lots of black soot around the joint at the head. Went back to a 150 this year and surprise! Same liveliness ! More is not always better !
Cheers! 8-)

Title: Re: Dyna swap- Now FLAMES
Post by Dave on 09/20/23 at 04:11:08

6C7F667F7277757E7F7B66160 wrote:

An engine that is a bit too rich runs smoothly, starts easily...and fools you into thinking things are great (when they really aren't).

An engine that is a bit too lean is often not smooth or steady as you open the throttle to accelerate or hold a steady throttle to cruise. They can also pop and backfire more than normal.

A properly jetted bike runs so much better than one that it too rich or too lean. There may still be some popping/banging while decelerating, as a closed throttle while slowing down or downshifting creates a lean condition....sometimes the stock carbs TEV just can't overcome that, and a more open exhaust makes the situation more noticeable.

When I first started jetting the Savage I went to the extremes to see the limits. I put in a main jet and rode the bike, then kept putting in bigger ones until I could feel the engine starting to choke under full throttle......then I put in smaller ones until I could feel it was too lean. Now I just reach for a #150 as it has proven to be the proper main jet for my 500'-800' elevation. I have ridden the Cherahala Skyway with this jet to 5,000' elevation and it still runs OK - however if I lived at that elevation a smaller jet might be in order. The #50 or #52.5 pilot jet are in the correct range - use the one that results in the mixture screw being 2-2.5 turns out for smoothest idle (must turn the idle speed down to around 800rpm for this adjustment). Then fiddle with the needle spacer to get smooth acceleration at partial throttle......keep adding washers until you feel a surge and uneven acceleration - then take out washers until the partial throttle acceleration becomes smooth.

Title: Re: Dyna swap- Now FLAMES
Post by ThumperPaul on 09/29/23 at 17:26:58

It does sound like jetting with the Dyna swap. With the Dyna, I landed at #150 Main and #55 Primary, and smaller spacer on needle, and about 1 turn out on the mix screw. I'm at sea level. I could have stayed at the 52.5 primary.... The 155 main was too big - lost its snappiness.

The flames may have been happening unnoticed with the stock exhaust. Is your valve lash in specs? Ticking valves are closing valves. Really quite valves may not be closing and seating. Poof out the exhaust pipe....