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Trouble shooting guide (Read 2616 times)
verslagen1
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Trouble shooting guide
06/19/14 at 09:07:02
 
This thread will be locked, to comment, please go to RSD thread of same name.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1404328411

We will list the common symptoms and try to provide you with a solution.

Most inexplicably... usually the problem is what you last worked on.   Huh

Most of these solutions are found in the tech section, some are also linked in the Tech Section Index
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« Last Edit: 07/23/14 at 12:55:21 by verslagen1 »  

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Re: Trouble shooting guide
Reply #1 - 06/19/14 at 09:09:06
 
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« Last Edit: 08/10/14 at 14:29:43 by verslagen1 »  

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Re: Trouble shooting guide
Reply #2 - 06/19/14 at 14:17:00
 
Won't Start


No lights or just clicks - dead battery
No lights or just clicks - bad contacts
Lights, push button and nothing - check your safeties - kill switch, clutch, kickstand, neutral.
Lights, push button and nothing - check your connectors.
Lights, 1 click and nothing - check you get power to the starter relay or stuck relay.
Lights, 2 clicks and a grunt - stator cover off?
Lights, 2 clicks and a grunt - decomp out of adjustment
Lights, 2 clicks and nothing - dead starter - remove and check with battery.
Starter spins, and spins and spins - Check your voltage, if below 10v, it won't spark.
Starter spins, and spins and spins - Check for spark.
Starter spins, and spins and spins - Check for gas, will a shot of ether start it?
Starter spins, and spins and spins - Check for compression.
Starter spins, exhaust smells flooded - check your air filter - wet?
Starter spins, exhaust smells flooded - gas puking out the carb vents? - bad/stuck float/valve.
Starter spins, clacks every revolution - check your decomp for stuck at full travel.
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« Last Edit: 03/24/16 at 14:46:58 by verslagen1 »  

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Re: Trouble shooting guide
Reply #3 - 07/09/14 at 12:34:05
 
Cut's out at speed
Backfires
Stutters

Test Your Petcock
Did you hit a bump? - check your kickstand switch
Blew a fuse?
Battery gone dead?
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« Last Edit: 07/17/14 at 07:20:46 by verslagen1 »  

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Re: Trouble shooting guide
Reply #4 - 07/09/14 at 12:40:51
 
Carb Issues

Lagging acceleration - Sticking slide - seafoam/snake oil or pull the carb and clean it.

Backfiring - can be too lean, but it also can be too rich.
what happens is that leftover gas accumulates in the muff and just waits for a breath of fresh air to ignite.

So the 1st thing to do is eliminate the fresh air.  check for loose header bolts and air leaks all along the header and muff using a lit candle, the flame will blow around when you're close to a leak.

For a stock bike at your altitude, it's generally best to leave it stock.

K&N drop in's or Cone filter's and a drilled muff's, tend to make it lean.

Taking out the snorkel or the door will make it lean too.

Tell us when it backfires as that's a clue as what to do.
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« Last Edit: 08/10/14 at 14:34:14 by verslagen1 »  

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Re: Trouble shooting guide
Reply #5 - 07/10/14 at 09:54:48
 
Bad Spark


Bad/fouled sparkplug - try a new one.
Check your battery voltage - less than 10v while starting is turning and you'll have no spark.
Bad TDI (aka brain box or incorrectly CDI) - leaving the ig on overnight can burn out a chip.
Loose connectors - check the sparkplug lead, coil leads, TDI connectors.
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Re: Trouble shooting guide
Reply #6 - 07/11/14 at 12:21:44
 
Noises

tapping on clutch cover
Squeaky Belt
Speedo
Headlight
Or Headlight
"card in the spokes" type noise, cadence follows wheel rotation - might be a loose pulley - re-torque pulley nut.
Mirrors... Body Panels... etc - When you hear a noise, use your free hand to grab a part. (keep it out of wheels and other parts that move) When the rattle stops, pull over and tighten it up.

Unidentifiable engine noise - adjust valves, check cam chain adjuster, loose flywheel nut, loose rotor nut.
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« Last Edit: 03/10/15 at 09:23:02 by verslagen1 »  

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Re: Trouble shooting guide
Reply #7 - 07/20/14 at 16:19:52
 
Won't Start - Lights, push button and nothing - check your safeties - clutch, kickstand, neutral.

Clutch and kickstand safeties can be bypassed with a paperclip (don't short to ground).
Kickstand has a green connector under the seat, remove connector & insert paperclip.
Clutch find the connectors on the clutch switch and short to each other.

Neutral has a connector under the tank, a single blue wire, disconnect and short harness side to ground
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Re: Trouble shooting guide
Reply #8 - 07/22/14 at 08:03:17
 
Smoking?

What color is the smoke?  Black, light blue, white?

Hold a mirror in front of the exhaust when it smokes.  Condensation will leave water droplets on the mirror.  Oil will leave an oily residue on the mirror.  Excess fuel will leave fuel on the mirror, that will evaporate off.
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Re: Trouble shooting guide
Reply #9 - 07/23/14 at 12:53:11
 
Oil Leaks?







Valve covers - replace cover o-ring
Oil Filter Cover - replace cover o-ring
Foot peg - retorque engine mount thru bolt
Fork seals - Replace Seals
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Re: Trouble shooting guide
Reply #10 - 12/26/15 at 10:09:09
 
How to test for spark

mjs3790225 wrote on 12/26/15 at 08:12:39:
Here are some videos and directions I put together for testing a couple parts of the ignition system.

How to test the pickup coil with two LEDs shoved in the connector.
  • Get two different color LEDs. 5mm size are fine. Blue and green are better choices but I used blue and red.
  • Disconnect your pickup coil connector.
  • Shove the LEDs into the connector coming off of the pickup coil.
    • The LEDs should be inserted with polarity opposite of each other.
  • While making certain you have the leads from the LEDs making good contact inside the connector, try starting the engine.
    • This will cause the rotor to spin around the pickup coil. Each time it passes the pickup coil it will cause the coil's magnetic field to collapse and shoot voltage through the LEDs. One LED will light up when it approaches the pickup coil, and the other will light up after it passes it.
  • If you are getting blinky lights, your pickup coil is working correctly.


Here is a really poor video of me talking about the theory behind this test and stimulating an old pickup coil with a wrench. The video was made as a series talking about something else so it isn't a great substitute for the instructions listed above.
https://youtu.be/EpfbL_aCoNA

How to test the ignition coil by forcing it to spark without the CDI



How to test the CDI box by forcing it to spark

NOTE: This test assumes you already know your ignition coil and pickup coil are both good.

First verify power to the CDI box. I am using the diagrams for a 1996 Savage.

  • Remove CDI box from wire harness
  • Remove spark plug from engine but keep in socket
  • Turn on key switch
  • Turn engine run/stop switch to run
  • Check voltages on the CDI wiring harness
    • Put a voltage meter on the Orange wire with a white stripe, and the black wire with a white stripe. You should have battery level voltage. This means your CDI box is getting power to actually think and make operations. If it isn't, you have a issue with power getting to your CDI box.
      • Check your you safety/bypass switches.
    • This same orange/white wire supplies positive power to the ignition coil.
      • If no power on this line, no power for your coil to make a spark


      Second, verify power can make it through your ignition coil to the CDI box
      • Put a voltage meter between the blue wire with yellow strip, and black wire with white stripe. You should have pretty close to battery voltage.


      Third, disconnect the pickup coil wires and halfway bypass it.
      • After the plug is disconnected, jump the orange wires together. Leave the green wire disconnected.


      Fourth, reconnect your CDI wiring harness.

      Fifth, ground your spark plug. (touch it to the head)
      • Use an alligator clip and ground the plug to a clean part on the engine case.


      Sixth, force the CDI to spark by dumping the pickup coil's magnetic field - look at the spark plug for a spark or listen for it
      • On the pickup coil's harness plug, tap the green wires together.
        • This sends a pulse to the CDI that is normally only made while the rotor is spinning around.
      • You should have gotten a spark out of this action. If you didn't your CDI is likely bad. (Or your rotor is currently sitting over the pickup coil. Move your engine a bit more ahead so it is past the timing mark).


      Video kind'a outlining this test
      https://youtu.be/KdEjrKjbUYM
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Re: Trouble shooting guide
Reply #11 - 03/24/16 at 14:46:17
 
Let's check the decomp.

put it in 2nd or higher.
bump the bike forward to rotate the engine.
bump it forward till you can rotate the decomp lever (left hand side, top of engine)
This indicates the engine is on the exhaust stroke.
Now try to start like normal (clutch in, neutral, etc.)
If it goes, your decomp is outta adjustment and the starter stalled on the compression stroke.

decomp out of adjustment
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