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What kind of charger - how may amps? Hooked to a charger I would have expected it to start. Just like jump starting a car with a dead battery. Unless it's just a trickle charger.  1or2 amps. That still probably isn't enough current, especially if the battery is toast.

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Has the bike run since you put it back together?

I think the next simple thing is a shot of starting fluid into the intake side of the carb like S-P suggested. See if you can get it to fire at all.

I wouldn't worry too much about the smoke till it's running.

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Jumping from a car battery, assuming everything else (spark, fuel etc) is OK I think it should have started.

Did you try some starting fluid so see it it would fire at all?

Did you check the valve clearances after you put the head cover back on after fixing the
head plug leak?

JBK wrote on 04/20/14 at 20:41:18:





http://suzukisavage.com/cgi-bin/YaBB.pl?num=1325991352

Could make it hard to start, or not start at all if they are far enough out of adjustment. Anyway It looks like you have looked at everything else. It's worth checking IMO, especially since you had the head cover off.

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That's the reason for trying a blast of starter fluid into the carb intake. If the bike will run - even for a few seconds-  on that, you've confirmed that it's a fuel problem.

JBK wrote on 04/21/14 at 21:09:46:


Not really. I think you might be just overlooking something simple or assuming something is OK when it's really not.

For the bike to run you need:

1. A battery that is capable of cranking the engine fast enough, and that also has enough juice while running the starter motor to fire the spark plug.

2. A combustible fuel/air mixture being introduced into the combustion chamber.

3.The valves have to be open when they should be and closed when they should be. They have to be CLOSED at TDC on the compression stroke.

4: Adequate compression - no broken rings, piston etc. which I'm pretty sure is not the problem here.

If those conditions exist the engine has got to run.

I think you need to verify that all the things you think are OK are actually OK, starting with the battery.

I don't know of any other way to figure this out except rechecking the things I mentioned above until you are positive the you've eliminated each one as the issue.

New battery in. Still nothing.  Turns over strong. On to carb.

After you clean the plug... check for spark..got power?

Make sure your petc0ck is off, remove the tube from the carb...turn on your petc0ck..fuel?

Put the tube back on, turn on your petc0ck....open the drain on your fuel bowl... fuel?

Tap your fuel bowl or take it off and see if the float needle drops ( it could be sticking)

Safety switches.... clutch, kickstand and neutral....

After that i'm lost.... only thing left would be the decomp....that I can think of....

Here is to hoping you find it....