SuzukiSavage.com - Replaced head cylinder cap, now bike won't start!

King Rico

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Replaced head cylinder cap, now bike won't start!
05/05/15 at 20:09:02

Hello Savages!

So, I finally replaced the fault stock head cylinder cap due to the infamous oil leak. It's a 2004 LS650 with 16xxx miles.
I followed the directions from a previous post (THANK YOU!) and for whatever reason the bike won't fire up. It wants to start but just cranks and won't turn over. I've been retracing my steps but I'm really at a loss.

Any ideas or suggestions are much appreciated!

Rico

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King Rico

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Replaced head cylinder cap, now bike won't sta Reply #1 - 05/05/15 at 20:15:06 What is the battery Voltage? Did you try Prime?
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gizzo Serious Thumper Offline SuzukiCabbage. It's Savage. Posts: 1318 Australia	Re: Replaced head cylinder cap, now bike won't sta Reply #2 - 05/05/15 at 21:53:28 All the rocker arms in place properly and decompresser not riding open? Spark plug cap connected to plug lead? Got fuel?
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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Replaced head cylinder cap, now bike won't sta Reply #3 - 05/06/15 at 04:02:05 Did you check valve clearances after reassembly? Spark plug gap is OK? You did reconnect vacuum hose to petcock?
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Replaced head cylinder cap, now bike won't sta Reply #4 - 05/06/15 at 04:08:11 Also make sure the compression release solenoid/cable is not holding the exhaust valves open a bit.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Replaced head cylinder cap, now bike won't sta Reply #5 - 05/06/15 at 07:39:29 We will wait to hear from you, that is a good list.
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King Rico

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Re: Replaced head cylinder cap, now bike won't sta
Reply #6 - 05/06/15 at 10:35:55

Wow, you guys are awesome! Thanks so much for the quick responses. Ill do my best to answer your comments thus far.

-I installed a Raptor Petcock about 3 months ago, so the vacuum line is plugged and not attached to the petcock.

-Spark Plug cap connected.

-Tank has 50% fuel

-I am concerned about the decom solenoid. It seems to snag after opening, when I press the ignition. maybe its normal? Maybe I didnt route it properly on the reinstall? Ill try to take a video of it.

- I will check valve clearances , battery voltage, solenoid cable and will replace the spark plug and then report back.

Thanks again!
Rico

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King Rico

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Replaced head cylinder cap, now bike won't sta Reply #7 - 05/06/15 at 22:44:54 Disconnect the decomp, put it in 5th, get the motor just past TDC Compression, then hit starter.
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verslagen1

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Re: Replaced head cylinder cap, now bike won't sta
Reply #8 - 05/07/15 at 07:16:09

justin_o_guy2 wrote on 05/06/15 at 22:44:54:

Disconnect the decomp, put it in 5th, get the motor just past TDC Compression, then hit starter.

You'll have more leverage over the motor in 1st than 5th.
bump it forward, not backward.
It's kinda hard to tell when you've gotten it to "TDC compression"
but this works too, TDC of the exhaust stroke and you can tell that you've gotten there by using your hand to turn the decomp lever. You can turn it by hand when it gets to there, pretty tuff otherwise.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Replaced head cylinder cap, now bike won't sta Reply #9 - 05/07/15 at 10:35:05 Think about it again, use fifth.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Replaced head cylinder cap, now bike won't sta Reply #10 - 05/07/15 at 11:35:28 justin_o_guy2 wrote on 05/07/15 at 10:35:05: Think about it again, use fifth. right 5th, I had confused starting with preparing to start.
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King Rico

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Re: Replaced head cylinder cap, now bike won't sta
Reply #11 - 05/08/15 at 06:39:31

Alright Savages,

Had a few hours in the garage last night with Hot Lips. The Decom solenoid was adjusted (appeared to be slightly riding open) and new spark plug installed.

Also adjusted the rocker arms to .004 using justin_o_guy2's recommendation. It it difficult to find TDC but I think I got close when I was able to wiggle the decom cable.

The bike fired right up! However im hearing a oh so slight tick from the top of the cylinder head, mostly on the left side. Ive never adjusted valves so I was a bit paranoid. Not sure if the noise was normal, since Ive never really just "listened to the bike".

I have a feeling I may need to readjust the rocker arms after the short test drive in my drive way.

As always, comments and ideas are appreciated!

Rico

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King Rico

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18098 Camp Springs, Kentucky Gender:	Re: Replaced head cylinder cap, now bike won't sta Reply #12 - 05/08/15 at 06:57:27 A valve/rocker tick is pretty normal on the bike - but you do need to be sure you really were at the correct TDC when you adjusted the valves. Adjusting them when the cam was just beginning to open or almost closing a valve would result in you getting too much clearance int the valves.
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