SuzukiSavage.com - 2002 Savage will not start

Don Sinclair

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2002 Savage will not start
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

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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: 2002 Savage will not start Reply #1 - 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..
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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: 2002 Savage will not start Reply #2 - 01/12/06 at 19:15:18 And charge that Battery !!!
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pgolden Ex Member	Re: 2002 Savage will not start Reply #3 - 01/12/06 at 19:15:49 Did you replace the vacuum line. Thats what lets fuel flow from the petcock.
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Don Sinclair Guest	Re: 2002 Savage will not startDon Reply #4 - 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
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Dynobob

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Re: 2002 Savage will not start
Reply #5 - 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 Grin

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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: 2002 Savage will not start Reply #6 - 01/12/06 at 19:22:54 I used to know a Don Sinclair...Are you in Portland??
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Dynobob

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Re: 2002 Savage will not start
Reply #7 - 01/12/06 at 19:28:57

SAMM wrote on 12/31/69 at 16:00:01:

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.

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Don Sinclair Guest	Re: 2002 Savage will not start Reply #8 - 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.
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Dynobob Serious Thumper Offline 2003 LS650 (with Supertrapp) Posts: 634 Northern Virginia Gender:	Re: 2002 Savage will not start Reply #9 - 01/12/06 at 19:55:40 Don Sinclair wrote on 12/31/69 at 16:00:01: 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.
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babbalou

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Re: 2002 Savage will not start
Reply #10 - 01/12/06 at 19:59:14

Don Sinclair wrote on 12/31/69 at 16:00:01:

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.

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.

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Had an S40 Jul '04-Jan '07

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Don Sinclair

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Re: 2002 Savage will not start
Reply #11 - 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.

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Savage_Greg

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Re: 2002 Savage will not start
Reply #12 - 01/15/06 at 07:05:34

Don Sinclair wrote on 12/31/69 at 16:00:01:

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.

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 Grin

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.

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don Sinclair

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Re: 2002 Savage will not start
Reply #13 - 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

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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: 2002 Savage will not start Reply #14 - 01/16/06 at 15:34:37 Time for a new spark plug !!! Go buy a couple they are cheap.........
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