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Mystery problem (Read 270 times)
mlittle
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Mystery problem
04/19/17 at 14:27:03
 
Hello.  I've got a 2011 Boulevard S40.  The reason I'm posting is that it has an ongoing engine problem which I've been unable to resolve.  

The engine wants to die while riding the bike.  It may run fine for a period of time - anyway from a few minutes to a much a 45 minutes into a ride.  After the trouble appears I have to blip the throttle to a great extent to even keep the engine running.  If I don't do this it will die immediately.  So that's the basic nature of the problem as it occurs while riding.

I've had it up to the Suzuki dealer, as well as a neighborhood mechanic.  Both times they rebuilt the carburetor, and both time the problem came back after the motorcycle set for a period of time.  (Anywhere from 2 to 4 weeks)  I'm not really sure what would explain all of these symptoms, and so I'm writing in hopes that someone can give me some suggestions.  Please let me know if you need me to provide any more details.

Thanks in advance for any help offered Smiley  
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verslagen1
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Re: Mystery problem
Reply #1 - 04/19/17 at 14:40:15
 
Test your petcock, thread in the tech section index.
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Re: Mystery problem
Reply #2 - 04/19/17 at 14:41:45
 
Do you still have the stock vacuum operated (automatic) fuel petcock on the bike?

The diaphragm in the petcock can go bad, and make all kinds of running problems.  Sometimes the diaphragm gets hard and no fuel flows - sometimes they get holes and flow too much fuel.

This forum suggests that you replace the stock petcock with one from a Yamaha 660 Raptor.   It is manual and very reliable - however you will have to learn to turn it ON to ride....OFF to store.

Look at the link below - it lists the official Yamaha part number of the petcock - don't buy a Chinese copy from eBay.  If you don't see the parts number listed or the white box it comes in - don't buy it.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1366651397
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mlittle
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Re: Mystery problem
Reply #3 - 04/20/17 at 08:55:01
 
This is super helpful guys...  I had  come to the point of about wanting to get rid of this bike.  The Suzuki dealer didn't seem to know anything about this issue, and I had had a long talk with them.  So this forum is truly a big help.

Yes.  Everything on the bike is 100% stock. (well except for the battery)
So I'll get on this right away and see if this takes care of the issue.  It had gotten bad enough where I couldn't even ride the thing any longer.

Thanks so much!
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justin_o_guy2
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Re: Mystery problem
Reply #4 - 04/20/17 at 09:17:55
 
Whatever "Solution  " they sold you was an exercise in ignorance. They shouldn't charge for a "Repair  " that doesn't fix the problem.
That they know so little about a bike they sell is sad. That they would charge for labor that doesn't solve the problem is something else..
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HAPPYDAN
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Re: Mystery problem
Reply #5 - 04/20/17 at 09:21:23
 
Listen to these guys. I did and I am eternally grateful for it. My S40 is a 2012, and at just over 1,000 miles, it conked out under hard acceleration going uphill. Sputter, sputter, blah. Having read their sage advice regarding that POS stock petcock, I had already ordered and received the Raptor (see tech section). Turned it to PRIME to get home, and changed it that day. Now over 5,000 miles, and nuthin' but smiles Smiley. Also if you use E10 pump gas, add a fuel stabilizer like STA-BIL. It helps a lot with the backfires and carb issues.
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koehlerrk
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Re: Mystery problem
Reply #6 - 04/20/17 at 10:05:10
 
Vacuum petcock... one of a handful of known problems with these bikes.

Picked up a 2003 with 18K miles for my wife. Bone stock, still had the brass plug in the carb! I've torn it apart, got a cam chain tensioner and head plug from Verslagen, and a Raptor petcock. Just ordered a jet set from Lancer, and that should take care of most of the issues for a while.

Forget the stealerships... the folks here have forgotten more about these bikes than most of the "service techs" will ever know.
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Kris01
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Re: Mystery problem
Reply #7 - 04/20/17 at 18:03:48
 
Dealerships around here can't count less than 4 cylinders.  Roll Eyes
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There's no problem that a full tank of gas and a sunny day can't fix!

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Re: Mystery problem
Reply #8 - 04/20/17 at 21:14:32
 
There are no dumb questions! You should always come here first,we can answer with  most of the info you need to fix your problems and we don't charge you for labor,
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justin_o_guy2
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Re: Mystery problem
Reply #9 - 04/21/17 at 10:53:27
 
There are no dumb questions..

Ohh, you have not heard some of the questions I have heard, then.
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Re: Mystery problem
Reply #10 - 04/21/17 at 11:08:19
 
There are more dumb answers than dumb questions .....  Cheesy
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Check out http://www.hogsforhospice.com/
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Re: Mystery problem
Reply #11 - 04/21/17 at 20:23:11
 
JOG ,Here's one ,can I build my bike into a three wheeler? but I already know the answer ,it's not a good bike to try it with ,the steering neck rake angle is 35 degrees and when you try to turn a corner the bike wants to keep going straight.
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Re: Mystery problem
Reply #12 - 04/22/17 at 03:48:01
 
Go to page one of the tech section on this site, there is an informative video on how to change the stock petcock to the Raptor 660 one.
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Completely stock 2010 S40, aftermarket rev counter and back pack, Airhawk seat pad
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Re: Mystery problem
Reply #13 - 06/02/17 at 10:48:13
 
Hey guys.  Just a quick update regarding the "mystery problem ".  It seems the petcock replacement has resolved the issue.  First my neighbor discovered that by turning the lever to "prime" the trouble could be circumvented.  Next I installed the new raptor petcock ( as directed). The whole thing took about 45 minutes, but I had to drain a lot of fuel. (that was the longest part). Anyway, its been running like a champion racehorse ever since.  

From a guy that was so fed up I was about to sell the thing - needless to say you all have my heartfelt thanks.
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Gary_in_NJ
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Re: Mystery problem
Reply #14 - 06/02/17 at 11:18:44
 
Another Raptor to the rescue.
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