Good afternoon,

I'm hoping someone can give me some advice about a problem I'm having with my Savage.  I bought a 1999 Suzuki Savage about three months ago.  It ran fine the first couple of weeks.  After that, it would start up fine, but once the engine got warmed up, it idles very rough and the engine dies unless the throttle is constantly forced.  It does not start back up right away after the engine stalls, usually I have to wait at least 15 to 20 minutes before it will start up again.

At first, I thought it was the carbs.  I'm not a mechanic, so I took the motorcycle to the Suzuki dealership. They took the carb off and told me that was fine, the problem was the aftermarket muffler that was installed on the bike.   He wanted me to spend 500 for a new stock muffler and he would put it on the bike.  I did not want to spend that much, so I ended up getting a muffler from a junkyard Savage.  It was a stock muffler and pipe, the only thing was that it was gutted.  He put it on and I took it home.  I'm still having the same problem, the mechanic told me to try adjusting the idle RPMs.  I did, still stalling after the engine warms up.  He still insists that the muffler is the problem, but I'm not sure if that is the problem.  Could that be the problem since it is gutted or should I check something else?  It only sputters and stalls once the engine is warm, runs like a charm when the engine is cold.  Please keep in mind, I'm a beginner motorcyclist and I'm not a mechanic.  My roommate is a bit more knowledgeable about motorcycles and can help but he is far from a mechanic himself.  

I would appreciate any advice anyone can offer.  I just want to get my Savage running properly and ride it out on the road without worrying about having to push it home.  Thank you  

Test your Petcock...

here's how...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1251932429

Hey girl, Welcome to the site. I would do as suggested, but I would also put a new vacuum hose complete with clamps and a new gas line complete with clamps. There are also two? little towers made of mesh inside your gas tank. It is not probable but certainly possible that these nylon screens could be clogged on a '99 bike. I am talking about a 30 min project for the experienced, or maybe an hour for others. Plus it's cheap. Sometimes a coil can break down when warm, but these bikes have far more petcock problems. Go to an auto parts store with the hoses and get the closest size. Good luck and happy riding.

If setting it on prime doesn't do it, you might want to check the tightness of the exhaust system, as the metal heats up it expands and things like the compression washer under the exhaust header might leak - or the pipe to muffler joint.  Welcome and enjoy the ride..and make the corrections one at a time so you'll know what it was; and please post the results.  It's gonna be another long winter.

Sweet!  When I set the petcock on prime, it works great!  Thank you so much!

So, in order to fix the issue, should I replace the petcock, the vacuum hose, and the gas line?

S Girl, A deteriorated hose can cause a clogging effect, or a pinhole can let air in the vacuum hose. Be patient and try the cheap, easy stuff first. Gas lines are usually taken for granted and not replaced very often. Again, patience is your friend. It lets you learn about your bike as you work slowly and carefully. We will be here tomorrow and the next day. As you work the systems out with the help of this forum, you give us a chance to help someone we will probably never meet. SOMEONE on here will eventually make a suggestion that works. And I guarantee it will be the last thing you check. Lots of experience on here. Let it work. Our rates are the lowest of any "shop".

That'll work..

BurnPgh wrote on 10/20/10 at 11:23:49:


I can't believe you said that! Now her Savage won't be stock without the spring thing. And you know what happens when you get away from stock---FUN!!