Question about 1996 Suzuki LS 650 Savage

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Extreme difficulty reving the engine

I just bought a troubled motorcycle from a guy I work with. It's a 1986 650 savage that had a blown engine, and he swapped out the motor with a 1996 650 engine. Since then, when you start it, it idles just fine until it warms up a bit, then it slowly revs down and stalls. While it is cold however, if you try to rev it quickly, it will simply stall, and if you slowly roll on the throttle, it will slowly rev up then as the rpms increase, it will start to backfire and miss.

Carb has been rebuilt for this issue, and the ignition module has been replaced. No better. Does this sound like the engine could be mechanically out of time? Or is there some difference between the two motors that could be messing me up?

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You should have CDI on the bike so I don't think timing is the issue. The carb may have been rebuilt but that doesn't mean the pilot circuit is clear. You will need to pull the carb and clear the idle circuit. While the carb is out, move the clip on the jet needle down one notch. Two may be needed but start with one.

ALWAYS have a fire extinguisher on hand when working on carburetors.
Remove the water trap bowl at the bottom of the petcock, (gas valve). Is there any water or trash in the bowl? Drain a cup of gas from the tank. Is there any water or trash in the cup? Dump it, clean it and re-mount it, ( not all bikes have a water trap bowl ).

Remove the float bowl and clean the entire carb with a spray carb cleaner from the auto parts store. Wear protective goggles to avoid getting spray in your eyes. Spray into all the little airways and fittings in the carb. Remove the idle screw and the air screw on the outside throat of the
carb and spray into the screw holes as well.
Be sure to put these two screws back in the same hole they came out of. IMPORTANT > do not tighten these two adjusters down. Only screw these in until they LIGHTLY seat. Now turn each adjuster one and one half turns outward. Put the rest of the
carb back together, clean the air filter and install the carb. Let the float bowl fill then start the engine.
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Posted on Jun 29, 2009

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