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General Category >> Rubber Side Down! >> Need help -- De-compression cable adjustment
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Message started by bentwheel on 02/22/05 at 15:07:13

Title: Need help -- De-compression cable adjustment
Post by bentwheel on 02/22/05 at 15:07:13

I am finally getting at my winter maintenance and maybe I have been out in the cold garage too long, but I don't understand this adjustment. Where is the actuator body that I have to pull? Is it part of the solenoid?

Title: Re: Need help -- De-compression cable adjustment
Post by rkutzner on 02/22/05 at 17:57:26

You've peaked my interest, where did you find out about this cable? I didn't notice it in the owners manual?

Title: Re: Need help -- De-compression cable adjustment
Post by bentwheel on 02/22/05 at 19:08:38

There is an automatic de-compression cable that is operated via an electric solenoid. The cable should be adjusted every 6,000km/4,000mi.
If you look near the front of the left chrome cylinder cover you will see the cable that operates the lever.

Title: Re: Need help -- De-compression cable adjustment
Post by Greg_650 on 02/23/05 at 05:40:20

Here's the seal underneath the lever.....can't find a good one of the lever though.
http://home.comcast.net/~gmdinusa/DeCompLever01web.jpg

Title: Re: Need help -- De-compression cable adjustment
Post by slavy on 02/23/05 at 07:33:58

Yes, it is part of the solenoid.
I checked in the Suzuku manual and they show the actator body. Basicaly You are checking the cable free play /3-5 mm/ in TDCC. Remove the sp. plug, remove the timing cover, remove the valve adj. cover and turn the engine counterclockwise. In TDCC check the cable free play and adjust with the 2 nuts if necessary.
Have all the fun!

Title: Re: Need help -- De-compression cable adjustment
Post by bentwheel on 02/23/05 at 13:03:00

Ok, ok I see it now. Thanks Slavy. You have to access the measurment from the rubber plug on the solenoid. My shaft travel measured 3.1mm so I adjusted it to the middle range of 4.0mm. This adjustment actually put more travel in the cable equaling less de-compression lever travel so I returned the adjustment to a finely tuned 3.3mm.

Title: Re: Need help -- De-compression cable adjustment
Post by PerrydaSavage on 02/23/05 at 14:50:05

Hi guys ... as usual, interesting and educational stuff for us Savage owners!
Read somewhere, that some Savage owner in Europe converted the automatic decompression to manual ... is this possible ... if so, how would you go about it (not that I have plans to do so ... I'm just curious ...)?

Title: Re: Need help -- De-compression cable adjustment
Post by bentwheel on 02/23/05 at 19:10:08

It certainly is possible to convert to a manual de-compression lever but I think the Savage method works well. I will say it is a bit of a Rube Goldberg, requiring an electric solenoid to move a shaft which pulls a cable that actuates a worm gear which engages a lever to open a valve near TDC. If you have electrical gremlins the solenoid may not do its job and the engine would be hard to start, if not impossible. My guess is the fellow in Europe simply bypassed the solenoid and installed a cable operated lever attached to the existing de-compression cable lever.

Title: Re: Need help -- De-compression cable adjustment
Post by klx650sm2002 on 02/24/05 at 00:26:49

My KLX has an auto de-compressor no solenod or lever just a centrifugal thing on the end of the exhaust cam so can't set the idle speed to low.

Clive W :D

Title: Re: Need help -- De-compression cable adjustment
Post by Kropatchek on 02/24/05 at 02:56:05

bentwheel wrote:

Your guess is right, that's excactly what they did.
I'm frequenting this German forum and have read all about it.
Greez
Kropatchek ;D

Title: Re: Need help -- De-compression cable adjustment
Post by Greg_650 on 02/24/05 at 05:31:07

Some of my older dirt bikes had manual decompression levers, too.

Title: Re: Need help -- De-compression cable adjustment
Post by bentwheel on 02/24/05 at 09:55:20

Yeah, I remember those too. They were popular in big bore two strokes. It was a much simpler set up though, consisting of a pop-up valve threaded directly into the cylinder head, operated via a cable from a bar mounted lever. On some bikes they served a dual purpose. For instance, I had a 1977 Bultaco Astro 360 (always loved that name) and when on a dirt track, coming down the end of the straight and entering the turn, instead of dialing down the throttle you would pull the de-compression lever instead to shuck off some speed while holding the throttle open.

Title: Re: Need help -- De-compression cable adjustment
Post by Greg_650 on 02/25/05 at 05:05:22

klx650sm2002 wrote:

My KLX has an auto de-compressor no solenod or lever just a centrifugal thing on the end of the exhaust cam so can't set the idle speed to low.

Clive W :D

A centrifugal thing? So below idle the exhaust valve is always partially open.

Title: Re: Need help -- De-compression cable adjustment
Post by slavy on 02/25/05 at 07:28:07

If I am correct the 500cc Bombardier quad /the one that is 4X4 and has Rotax engine/ is the same way. If the engine speed is below 400RPM the EX valve is open. The reason is if You have to use the pull start You realy need the decompressor.

Title: Re: Need help -- De-compression cable adjustment
Post by bentwheel on 02/25/05 at 19:40:04

klx650sm2002 wrote:

My KLX has an auto de-compressor no solenod or lever just a centrifugal thing on the end of the exhaust cam so can't set the idle speed to low.

Clive W :D

Suzuki also used this method with their old DR350, probably the current DR650 as well.

Title: Re: Need help -- De-compression cable adjustment
Post by klx650sm2002 on 02/25/05 at 23:56:04

The centrifugal thing is pressed on to the end of the cam and is liable to come loose so I've had mine welded,no more problem.Tickover is 1200 rpm+

Clive W :D

Title: Re: Need help -- De-compression cable adjustment
Post by Greg_650 on 02/26/05 at 06:28:23

I didn't know all this :o

Cool.

Title: Re: Need help -- De-compression cable adjustment
Post by slavy on 02/26/05 at 07:13:59

Most of the Hondas had a cable between the kick starter and the decompressor. When You are kicking You automaticaly pull the decompressor. Yamahas have a small lever /like a triger/ on the handebars and You use it to be able to get the piston to TDCC.
LS650 just made this fansier.

Title: Re: Need help -- De-compression cable adjustment
Post by Greg_650 on 02/26/05 at 07:23:15

I remember the cables on the Hondas and the lever on the Yamahas. And oh yes, I remember kick starting a friend's XT500 after it had gotten stalled in a mud hole. It had a TDC indicator and decompression....but once stalled like that we'd have to take turns kicking to get it going again. What a monster.

Title: Re: Need help -- De-compression cable adjustment
Post by bentwheel on 02/26/05 at 09:25:51

If you are interested in seeing more on Suzuki's centrifugal de-compressor , check out the link below. It turns out this set up leads to rocker arm failure.

http://www.dr350.kenet.co.uk/camgear.php

Title: Re: Need help -- De-compression cable adjustment
Post by klx650sm2002 on 02/27/05 at 00:19:08

The valve gear on KLX is bucket and shim which I like.

Clive W :D

Title: Re: Need help -- De-compression cable adjustment
Post by Jooky on 08/07/06 at 02:34:39

How can I see that the engine is at TDC, in manual I read both rocker arms must have free play. I have been rotating engine clockwise severaltimes and can see nothing.

slavy wrote:

Title: Re: Need help -- De-compression cable adjustment
Post by vroom1776 on 08/07/06 at 09:10:08

second post in this thread:

this thread (http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1151938664)

Title: Re: Need help -- De-compression cable adjustment
Post by MacAttack on 08/07/06 at 17:34:37

My XR650 has a manual decompression lever AND an automatic one. On top of that, there's a reduction gear on the kickstarter. How else would you start a 10:1 compression 650 single without going over the bars?
Actually, the manual lever is for clearing out the gas when you crash the bike. It instantly floods, and one needs to turn the gas off, pull the compression release, open the throttle all the way, and kick ten times. Then close the throttle and kick as normal. Life without an electric starter. The upside is you get 55 hp. with less than 300 lbs.

Title: Re: Need help -- De-compression cable adjustment
Post by barb36jack31 on 08/08/06 at 19:08:01

I grew up on old British singles. Gold Star, Ariel Red Hunter, Norton etc. They all had manual compression releases. Do it right and the starting drill worked every time. Do it wrong and Much Cuidado, Amigo! You do the fastest one legged deep knee bend in the world!

Jack H.