SuzukiSavage.com - Found the problem, what next?

DocNeedles

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Found the problem, what next?
04/12/08 at 14:00:21

I finally found out what the problem was with my 86 Savage without much help from the dealership. I had been running rich with my new carb and couldn't find out what the problem was, and not having a workshop to try fixing it. Someone suggested disconnecting the vacuum tube and turning fuel valve to "Pri" and it worked no carbon contaminating my plug and the bike runs well (except for now having to adjust idle jet since it was on the leanest idle jet, and 3rd gear jet needs changing).
Thanks for all of the help and suggestions given by all of you.
Now the next question is is there a replacement kit for rebuilding the fuel valve and vacuum? I imagine in the vacuum part there is a diaphragm that needs replacing. I contacted the dealer and they said that there is no rebuild kit and a new fuel valve and all is $135.00.
Does anyone know if there is a rebuild kit out there?
If there isn't will it be a problem in capping my vacuum line and running on "Pri" as long as I turn it off when I park it? I read in this section about someone leaving it on Pri and the dangers of fuel contaminating the oil. Don't want that to happen.
It is fantastic being able to ride without worrying about the plug fouling!
DocNeedles

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Bobbert Serious Thumper Offline CHOP IT Posts: 836 Los Angeles, CA Gender:	Re: Found the problem, what next? Reply #1 - 04/12/08 at 14:02:30 I run mine in PRI only because I distrust my vacuum. Its spotty. Just make sure you turn it off every time. I've had no problems with my bike on PRI
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rigidchop Serious Thumper Offline don't feed the drama llama Posts: 1105 ravenswood wv Gender:	Re: Found the problem, what next? Reply #2 - 04/12/08 at 14:09:16 i think i paid close to $80 from bikebandit.com worth every penny.
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grandpa Senior Member Offline Old but not cold!!! Posts: 259 Bartlett TN Gender:	Re: Found the problem, what next? Reply #3 - 04/12/08 at 15:47:03 There is a tech post on converting from vacuum operated to manual operted fuel valve. Just search the tech posts and you will find it.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 29042 L.A. California Gender:	Re: Found the problem, what next? Reply #4 - 04/12/08 at 16:26:09 Other options? I've been looking at swapping tanks out from other bikes for some time. Quite a few suk's look like they are the same configuration as our bike and don't have vacuum operation.
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DocNeedles

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Re: Found the problem, what next?
Reply #5 - 04/19/08 at 17:04:08

rigidchop wrote on 04/12/08 at 14:09:16:

i think i paid close to $80 from bikebandit.com worth every penny.

Thanks rigidchop. I couldn't connect with bikebandit ordering from where I live in Canada (seems ordering they don't recognize Canadian provinces), but I did contact Ron Ayers and they are mailing it to me for around $80.00.
DocNeedles

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DocNeedles

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Re: Found the problem, what next?
Reply #6 - 04/19/08 at 17:06:03

Bobbert wrote on 04/12/08 at 14:02:30:

I run mine in PRI only because I distrust my vacuum. Its spotty. Just make sure you turn it off every time. I've had no problems with my bike on PRI

I have started running mine on PRI with the vacuum pinched off and it is running like a dream, and I did order a new fuel valve.
DocNeedles

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DocNeedles Senior Member Offline I love YaBB 1G - SP1! Posts: 272 British Columbia Gender:	Re: Found the problem, what next? Reply #7 - 04/19/08 at 17:07:48 grandpa wrote on 04/12/08 at 15:47:03: There is a tech post on converting from vacuum operated to manual operted fuel valve. Just search the tech posts and you will find it. When i get my new fuel valve I will rebuild the old one as per tech section. DocNeedles
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Sandy Koocanusa Serious Thumper Offline Don't blame me. I didn't vote for him. Posts: 1878 Bigfork, MT Gender:	Re: Found the problem, what next? Reply #8 - 04/19/08 at 17:11:58 I think your dealer may be sticking it to you. I ordered a new petcock for my '87 today. It cost $65.00 USD. That was from my local Suzuki dealer. -Jason
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Steve M

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Re: Found the problem, what next?
Reply #9 - 04/19/08 at 21:50:41

PLEASE Read the following NOTE IMPORTANT FOR SAFETY.
There is a prime and a normal position for a reason. In normal when you stop engine fuel is cut off to the carb. Prime is only supposed to be for flooding a dry carb up.

If you run on prime always remember to turn petcock of when you refuel and don't open again until you are ready to ride off.
If it is set to prime the line to the float chamber is open right through.
You fill tank with cold petrol from an underground tank, then you go pay, get drink etc. While you are gone the heat from engine and warm air starts to warm the petrol. Petrol and the air space in tank expands and if your petcock is on normal position pressure vents through filler cap.
If petcock is on prime the pressure can over power your float on carb bowl causing it to overflow through carb jet holes in engine intake. I know someone who did this with a Yamaha XJ900 that has same type of petcock and all 4 carbs overflowed through the jet holes in engine intakes. It caught fire and destroyed his bike!

If you look up an online parts store called wemoto.com and browse to Suzuki savage they stock lots of savage parts.
You can get a repair kit for petcock for about $15 that includes all seals and diaphragm, I just did mine last week and put it together with a smear of silicon grease on the internals. It works like a dream now and moves smooth and easy between positions.

Also don't forget if you run on prime then you don't have a reserve.

I know I have carped on about it here but please remember and be safe!

It is based here in the UK but they ship worldwide and postage on small items won't be that much. Or perhaps the repair kit can be got in the USA?

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Steve M Junior Member Offline SuzukiSavage.com Rocks! Posts: 60	Re: Found the problem, what next? Reply #10 - 04/19/08 at 21:56:04 Further to my last if you can't get hold of a repair kit I could buy some and post to one of you to pass around to any folk who want one if your interested. ( I would just want the cost of buying and posting). Could save some of you quite a bit of money.
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DocNeedles Senior Member Offline I love YaBB 1G - SP1! Posts: 272 British Columbia Gender:	Re: Found the problem, what next? Reply #11 - 04/20/08 at 14:02:28 Sandy Koocanusa wrote on 04/19/08 at 17:11:58: I think your dealer may be sticking it to you. I ordered a new petcock for my '87 today. It cost $65.00 USD. That was from my local Suzuki dealer. -Jason Thanks, Jason. The price was $65.00US and with shipping to Canada came to $80.00. DocNeedles
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DocNeedles

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Re: Found the problem, what next?
Reply #12 - 04/20/08 at 17:14:09

Steve M wrote on 04/19/08 at 21:50:41:

PLEASE Read the following NOTE IMPORTANT FOR SAFETY.
There is a prime and a normal position for a reason. In normal when you stop engine fuel is cut off to the carb. Prime is only supposed to be for flooding a dry carb up.

If you run on prime always remember to turn petcock of when you refuel and don't open again until you are ready to ride off.
If it is set to prime the line to the float chamber is open right through.
You fill tank with cold petrol from an underground tank, then you go pay, get drink etc. While you are gone the heat from engine and warm air starts to warm the petrol. Petrol and the air space in tank expands and if your petcock is on normal position pressure vents through filler cap.
If petcock is on prime the pressure can over power your float on carb bowl causing it to overflow through carb jet holes in engine intake. I know someone who did this with a Yamaha XJ900 that has same type of petcock and all 4 carbs overflowed through the jet holes in engine intakes. It caught fire and destroyed his bike!

If you look up an online parts store called wemoto.com and browse to Suzuki savage they stock lots of savage parts.
You can get a repair kit for petcock for about $15 that includes all seals and diaphragm, I just did mine last week and put it together with a smear of silicon grease on the internals. It works like a dream now and moves smooth and easy between positions.

Also don't forget if you run on prime then you don't have a reserve.

I know I have carped on about it here but please remember and be safe!

It is based here in the UK but they ship worldwide and postage on small items won't be that much. Or perhaps the repair kit can be got in the USA?

This is great information!! I was wondering about the reserve and I know my fuel level is low and my gas station is about 10 miles away so it is good to be aware of this. Also the info about the rebuild kit. I was surprised that I couldn't find any available cause I thought that all fuel valves could be rebuilt. I have been maing sure that I turn the valve to regular setting every time I get off the bike.
Thanks again.
DocNeedles

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steely

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Re: Found the problem, what next?
Reply #13 - 04/20/08 at 19:00:22

DocNeedles wrote on 04/20/08 at 17:14:09:

Also the info about the rebuild kit. I was surprised that I couldn't find any available cause I thought that all fuel valves could be rebuilt.
DocNeedles

As far as I am concerned, they can. However, the last time I tried to rebuild a Suzuki vacuum actuated petcock that there was a rebuild kit available for, I nearly went mad chasing problems. I finally bought a new petcock and just called it good. It worked.

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1999 Suzuki Savage

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Steve M Junior Member Offline SuzukiSavage.com Rocks! Posts: 60	Re: Found the problem, what next? Reply #14 - 04/21/08 at 11:48:48 I agree Steely if you can get a new one for $65 it gotta be the best option, I only suggested repair kit as some one had said a new one was quoted very expensive. At a reasonable price a new one has to be the best option every time.
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