Okay, I was out riding my '03 Savage on a beautiful Sunday afternoon.  I had been riding down a highway and through neighborhoods looking at Halloween decorations for about two hours with no problems.  I started towards home and on an open part of the highway was running just over the speed limit of 45 mph (~47 mph) and had just passed a slower moving truck.  That's when I noticed what felt like a little sputter and a momentary loss of power (like it wasn't getting gas), so I opened the throttle a bit more.  It cleared briefly and then went back to sputtering and finally stalled.  I pulled over, double checked that I did indeed have fuel (I did) and even changed the petcock to pri just to make sure I should be getting gas even if the vacuum system was acting up (didn't know that it had already been removed by previous owner).  I restarted no problem and rode ~1/2 mile before it sputtered and died again.  This time, I could do nothing to get it to restart and run.

So I got help and trailed it home.  Several people had suggested a fuel filter clog, so using Clymer's I pulled the tank and the fuel filter.  It was completely clean, no debris in the tank or on the filter.  In fact, when I pulled the fuel line from the carburetor, the fuel ran out cleanly and easily.  I did try to open the petcock to check the diaphragm (not sure if that's actually a good idea), but wasn't able to break the seal.  So I put it back together.

I figured it might make sense to pull the carburetor and check it since it seemed to be a lack of gas getting to the engine properly.  So I disconnected everything, but can't seem to figure out how to physically remove it as the battery box doesn't allow it to be slid back as Clymer's suggests and no way I pull seems to provide enough gap to free the carburetor.  

I admit I'm a newbie.  I have some mechanical experience, but not with troubleshooting as I've always just worked with my Dad or as directed by an A&P mechanic.  Now I'm at a loss as to what to do next.  I'd be appreciative of any further troubleshooting ideas besides trailering it to the mechanic (which I guess I'll do if I can't get any further, but would really prefer not to).  It just frustrating that I'm missing the beautiful riding weather here in Houston!!!

Dahlia wrote on 11/08/09 at 13:33:39:


I always remove the battery box before removing the carb. You can remove the carb with the battery box in place but it is a pain in the a$$. Just pull out the battery and remove the four bolts in the bottom of the box that hold it in and pull the box.

Are you saying that you do not have a vacuum petcock on your bike? Did I read that right?

Interesting, I know some folks on here have altered their vac petcocks to manual but I do not know the procedure. It could be a petcock issue (but do not quote me on that). If you want to replace the petcock, go with a Raptor petcock, it is a direct swap, it is a manual petcock and cheaper than trying to find a stock replacement.

  The last thing you want to do is take that carb apart,I've had a motorcycle for 20 years and the carb was never apart.

Toymaker wrote on 11/08/09 at 14:15:09:


Thanks Toymaker, I didn't want to give too much advise about an altered petcock as I have never dealt with one. I figured someone here would know.

I'd either read up on the manual petcock mod and do it, or swap out for a raptor petcock.  Or replace it with a new stock petcock.

Anyway, that reputable shop should've let you know that the petcock wasn't working to stock config.  Not very reputable in my book and concidering it was a new2you bike.

I'd go straight to soaking the carb in seafoam (fill soak and drain)
sounds like you got something caught in your jets.
This carb is pretty simple, look up the procedure in the tect section.
BTW it was written by a girl, so I know you can do it if you want to.

I use Stabil marine stabilizer and performance improver - year round -
where I live you never know if the fuel is ethanol or not - there are no laws for stickers on pumps -
anyway - the marine stabil has 4x as much detergents and 2x as much top end lubricating oils -

I also use it in my lawnmower and snow blower - all the time.....
great stuff---!

This sounds exactly like the same problem I have been having.  Love the suggestions.  The only difference is that the bike is completely stock on the engine side.  Rides great through the curves even up to 55 and 60.  Hit a long straight away and it sputters and dies like there's no fuel.  Usually moving it to RES keeps it going and after a few minutes changing back to ON works fine for a while again.