Kawabuggy
08-01-2009, 12:32 PM
First post-so let me say THANKS for any/all help that is offered.
I am working on a Suzuki Z400, 2003 model year. It belongs to my buddy that rides with me. He called me the other day and told me that the clutch was out on his bike. He said he could release it all the way, and only when the lever was all the way out would it move. So, he brought it over to my shop so I could put a clutch in it. When it got here, I tried to start it to confirm that the clutch was bad-but it would not run! It will start up, idle really rough, and then die if you don't keep revving it.
So, I did verify that it does need a clutch, and I proceeded to put the clutch in it. When I went to drain the oil-there was more gas than oil coming out of the motor... I figured he must have left the gas on while it was in the back of his truck, and gas got past the floats and flooded the engine. No big deal.
After putting the clutch in I put fresh oil in it, & then pulled the carb off to check for dirt/debris in the needle & seat & jets. Carb had a little bit of junk in the bottom of the bowl but not much. I noticed there are 3 jets in this carb. I pulled all 3 to clean them with carb cleaner and blow them out with compressed air. Here is my first problem-ONE of them seems like it is either NOT DRILLED all the way through, or it is completely plugged up with something that is VERY HARD. Can anyone here confirm if one of the jets is NOT drilled all the way through? I don't want to start pushing something through there and damage it if it is supposed to be this way. Most bikes I have worked on the jets are drilled all the way through, but this is the first work I've done on a Suzuki and don't want to mess it up!
So, that's my first question-are all 3 jets supposed to be drilled all the way through?
I cleaned the carb and put it back on the bike, installed an in-line fuel filter, but the bike still will not run. It will start up and idle rough and stall unless you keep revving it, or adjust the idle way up. If you adjust the idle way up, it still won't hold a set RPM, it will fluctuate several hundred RPM like you are still revving the gas, letting off, revving the gas, and letting off.
I am now checking the valves. I have the spark plug out, and the valve cover off, I was trying to get the piston to TDC, and even with the spark plug out, in gear, trying to push the bike to make the piston move, the back tires just skid.. I kid you not, it has that much resistance even with the plug out. I was able to get it to turn over so it is not seized. I'm afraid there may be bigger problems, but need to eliminate the valve adjustment and jet issue to be sure.
I'll do a compression test on it next but if it has bad crank bearings, the compression test won't tell me that.
If anyone can offer me any guidance, I would appreciate it! This is my first time working on a Suzuki and I want to be able to get it figured out. My buddy DOES NOT own a manual, and DOES not believe in proper maintenance so this bike is a handful. He wonders why his bike only runs about half the time. I honestly think it has the original chain & sprocket (can you say shark fin?) on it..:eek:
________
Fix Ps3 (http://fixps3.info/)
I am working on a Suzuki Z400, 2003 model year. It belongs to my buddy that rides with me. He called me the other day and told me that the clutch was out on his bike. He said he could release it all the way, and only when the lever was all the way out would it move. So, he brought it over to my shop so I could put a clutch in it. When it got here, I tried to start it to confirm that the clutch was bad-but it would not run! It will start up, idle really rough, and then die if you don't keep revving it.
So, I did verify that it does need a clutch, and I proceeded to put the clutch in it. When I went to drain the oil-there was more gas than oil coming out of the motor... I figured he must have left the gas on while it was in the back of his truck, and gas got past the floats and flooded the engine. No big deal.
After putting the clutch in I put fresh oil in it, & then pulled the carb off to check for dirt/debris in the needle & seat & jets. Carb had a little bit of junk in the bottom of the bowl but not much. I noticed there are 3 jets in this carb. I pulled all 3 to clean them with carb cleaner and blow them out with compressed air. Here is my first problem-ONE of them seems like it is either NOT DRILLED all the way through, or it is completely plugged up with something that is VERY HARD. Can anyone here confirm if one of the jets is NOT drilled all the way through? I don't want to start pushing something through there and damage it if it is supposed to be this way. Most bikes I have worked on the jets are drilled all the way through, but this is the first work I've done on a Suzuki and don't want to mess it up!
So, that's my first question-are all 3 jets supposed to be drilled all the way through?
I cleaned the carb and put it back on the bike, installed an in-line fuel filter, but the bike still will not run. It will start up and idle rough and stall unless you keep revving it, or adjust the idle way up. If you adjust the idle way up, it still won't hold a set RPM, it will fluctuate several hundred RPM like you are still revving the gas, letting off, revving the gas, and letting off.
I am now checking the valves. I have the spark plug out, and the valve cover off, I was trying to get the piston to TDC, and even with the spark plug out, in gear, trying to push the bike to make the piston move, the back tires just skid.. I kid you not, it has that much resistance even with the plug out. I was able to get it to turn over so it is not seized. I'm afraid there may be bigger problems, but need to eliminate the valve adjustment and jet issue to be sure.
I'll do a compression test on it next but if it has bad crank bearings, the compression test won't tell me that.
If anyone can offer me any guidance, I would appreciate it! This is my first time working on a Suzuki and I want to be able to get it figured out. My buddy DOES NOT own a manual, and DOES not believe in proper maintenance so this bike is a handful. He wonders why his bike only runs about half the time. I honestly think it has the original chain & sprocket (can you say shark fin?) on it..:eek:
________
Fix Ps3 (http://fixps3.info/)