2005 Speedmaster wouldnt start and found airbox full of fuel and I think fuel has found it way to the sump.

It means one of the three carbs is not getting the float needle seating in the float needle seat properly.could be a bit of dirt or a hair in there or a split float or even a worn needle or float needle seat oring .get the carbs out and have a look at them. Undo the airbox push it backwards undo all the inlet clamps and Airbus clamps and wiggle the carbs out the left side of the bike ,it's tricky and a tight fit.

Might be fuel leaking from overflow. Perhaps the float valve is stuck or damaged, allowing the float bowl to overfill. Slight chance tapping on side of carb may seat the valve. If not, it will probably have to either be set, or replaced. Could possibly have some "gunk" stuck in the valve seat from the cleaning. It only takes a tiny speck of debris to hold the valve open, causing flooding. Another possible cause is that during the cleaning, the tab that adjusts the level of the float valve got bumped, changing the level.

How long has the bike been sitting? Sounds like the carbs may be gummed up,and in need of a professional cleaning,and re-synchronizing.

Do a compression test, you could have bent a valve.

Yes, you are right. It is the fuel pump. Fix or Replace and your good to go.

A customer of mine wanted me to change his fuel pump, because his didn't work.
When i was taking it off the bike i noticed a broke wire - fixed the broke wire and the fuel pump worked - check the wires to it too. It happens, saved him alot of money.

Happy Holidays

Hi Kevin, the fuel entering your airbox is likely coming through the vacuum hose from the top of the carby. You may have a tear in the rubber diaphram or the lip has curled or squeezed, allowing fuel to enter through the hose. If your bike is running alright otherwise, this is a relatively easy/cheap fix. The carby parts are available from/through all bike dealers and complete carby's are available secondhand from dismantlers or ebay at comparitive prices to the parts. The sight below has exploded view diagrams of your bikes components with parts lists for your ease of identification.
Cheers.


http://www.cmsnl.com/suzuki-dr200-se-2001-2005-usa_model15947/partslist/

I have found that on a tyre change that the discs get damaged (warped) by the person that removes the tyre. They lay the wheel on it side which is a direct contact with the discs to the surface, aply pressure to work on wheel and this way they bend or warp the disk.

usually when the needle and seat are stuck, the gas will run out of an overflow on the side of the carb, unless those are plugged for some reason, then obviously the gas will flow where ever it can. is the machine 2 or 4 stroke?,

there is no way for fuel to get passed the rings right? So if you filled the head with fuel, it would just work its way down the exhaust pipe and out the back, just like its doing. The only way of getting fuel into the sump is; if you have seriously bad rings (it would be burning oil) OR if its getting through the breather system. I don't even think if the injectors were on full-time, it still wouldn't get into the sump... very strange. Are you sure its not coolant? A serious coolant leak can be completely unnoticeable from the outside, but catastrophic to the inside. __________________

there is no way for fuel to get passed the rings right? So if you filled the head with fuel, it would just work its way down the exhaust pipe and out the back, just like its doing. The only way of getting fuel into the sump is; if you have seriously bad rings (it would be burning oil) OR if its getting through the breather system. I don't even think if the injectors were on full-time, it still wouldn't get into the sump... very strange. Are you sure its not coolant? A serious coolant leak can be completely unnoticeable from the outside, but catastrophic to the inside. __________________