Stuck in Zacatecas, Mexico

Discussion in 'The Garage' started by jrzyguy, Dec 19, 2012.

  1. jrzyguy

    jrzyguy Restless

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    I'm not sure if I'm posting this request for feed back in the best spot, as any help will be appreciated. I have an '09 DR 650. It began acting up about a week ago...all of the issues I'm about to list happened inconsistently...hard starting (needed to hold throttle open to start), would shut off at idle, hesitation at varying RPM's, and finally it wouldn't start at all.
    A tech at the Suzuki dealer in Zacatecas took the carburetor apart, inspected and cleaned it. It still didn't start. He installed new plugs (old plugs looked like it was running rich) and checked for spark (good) and it still won't start. Install new gas, same.
    The tech also checked the timing and it was correct.
    When trying to start it, in order to hear anything encouraging from the engine, the throttle must be open. It tries but won't start.
    Question...could it be a faulty CDI, a coil, a bad ground, or something else? Feedback from anyone with DR 650 experience will be appreciated.
    Finally, I'd prefer resolve my problem here and to continue my trip, but will ship the bike home if I have no other option.
    #1
  2. Jazz62

    Jazz62 Long timer

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    Just wild guessing but if it's running rich could you have an airflow problem, dirty filter etc?
    Also, didn't read that you tried looking at the fuel filter. Did you? Good luck and keep us posted.
    #2
  3. jrzyguy

    jrzyguy Restless

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    Thanks for the reply. The tech cleaned my air filter, the air box, and the boot between the air box and the carb. I spend the day watching him...he was very thorough. And I did have an in-line fuel filter, but removed it. So again, thank you.
    #3
  4. DaveRMS

    DaveRMS Long timer

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    These two indicate a clogged pilot jet. It wouldn't be the first time that someone cleaned a carb and didn't actually get it clean. Pull the pilot jet and inspect all the holes. Clean them with a very fine strand of wire and compressed air. A droplet of water can clog it. Clean every passage of the carb with a pipe cleaner and air.

    It doesn't sound electric at this point.

    I wouldn't place too much on reading the old plug. It tells the story of many thousands of miles. The new plug says a lot more about how the bike is running today.

    Good luck and don't give up. Take it to another mechanic if you need to. Someone else in that town can fix motors. Even a lawn mower guy knows how to deal with fuel and spark.

    Dave
    #4
  5. H96669

    H96669 A proud pragmatist.

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    I know nothing about them DRs, however I want to buy one and take it to Mexico so I absorb the info on them.:ear

    Fuel filters, looks like there are 2 of them, one at the petcock and one at the carb.

    http://www.advrider.com/forums/showthread.php?t=483289

    I am surprised the "tech" didn't try to spray gasoline in the carb as he tried to start it. If that gets the bike going, even temporarily, certainly would point to a fuel supply problem.:wink:

    Another thing you could try if you suspect ignition problems is to try starting the bike in the dark just to make sure the spark isn't jumping somewhere. That happened to my little XR.Easy diagnostic once I tried that.....not so in daylight. You can at the same time spray water at the plug wires/coil, if either is cracked you may see the spark jump.

    You could also remove the spark plug wires, if they are removeable as I think, and do an Ohm test on them. If they are carbon wires you may want to twist/bend them with the meter connected. My bike was giving me weird readings doing that, continuity then not.....damaged inner carbon core.:huh
    #5
  6. D.T.

    D.T. Difficult but useful

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    How many miles? Check compression. Valve clearance checked lately?

    I'd be surprised if they can't fix it. :huh
    #6
  7. scooteraug02

    scooteraug02 Dog Rancher

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    Could your petcock be messed up/ clogged? I have a DRZ400 and it has that petcock that has off on reserve and free flow.

    Don't know if the 650 has a similar carb to the 400.

    I would post on thumpertalk.com and thumper section of ADVrider.

    http://www.advrider.com/forums/showthread.php?t=135295
    #7
  8. jrzyguy

    jrzyguy Restless

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    Dave,

    Thank you for your suggestion. So I clean out the pilot jet!

    Jim
    #8
  9. jrzyguy

    jrzyguy Restless

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    I replaced the petcock before I left because it wasn't working properly. I'll look into Thumpertalk...thanks for the suggestions.

    Jim
    #9
  10. jrzyguy

    jrzyguy Restless

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    The bike has 6,000 miles on it, good compression, and proper valve clearance.
    #10
  11. concours

    concours WFO for 41 years

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    SUCK, SQUEEZE, BANG, BLOW.... Compression TESTED? What reading? The spark tested? Jumps a good distance, blue spark?

    If it turns out your spark is poor, intermittent, check kill switch wiring, switch, ignition switch, coil, ignition stator. Good luck
    #11
  12. mark883

    mark883 and the mysterians

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    I'll cross post this to the Is Mexico Safe thread.

    There's a few inmates residing in Mexico that may have ideas or help.
    #12
  13. tricepilot

    tricepilot El Gran Payaso

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    That could present a problem cancelling the bike's TVIP, if that's important to you.
    #13
  14. acejones

    acejones Long timer

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    Sure sounds like a Carb. I've had my fill of those tiny pilot jets.
    #14
  15. SikDMAX

    SikDMAX Been here awhile

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    Any update buddy?
    #15
  16. barko1

    barko1 barko1

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    Like someone else said might try seeing if it starts on starter fluid. Besides the pilot a bad float level can cause problems, any gas getting into the crankcase or airbox? If you ship and need a place to stash it I'm just an hour North of the border and have space.
    #16
  17. SeanF

    SeanF -

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    I will second the recommendation to check the little fuel filter in the carb's fuel inlet pipe.

    "needed to hold throttle open to start" sounds to me like fuel delivery.

    Good luck & let us know how it goes. :thumb
    #17
  18. eakins

    eakins Butler Maps

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    jim sent this email back

    Bill,
    Thanks again for getting back to me. Unfortunately, we redid the carb cleaning today (very thoroughly) and the bike still did not start. I am quite certain now that it's an electrical issue.
    The dealer isn't optimistic about me leaving the bike with him and sending electricial components down to Zacatecas. He isn't familiar with DR's and can't promise me a running bike. What are your thoughts?
    Jim
    #18
  19. eakins

    eakins Butler Maps

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    i recomended he spray starter fluid into the carb to verify 100% it's not fuel.
    he has spark so cdi is good? timing chain jumped maybe???
    #19
  20. ER70S-2

    ER70S-2 Long timer

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    Since your bike is almost new, we can skip some issues.

    We don't know how much you know, so I don't mean to talk down to you or your mechanic.

    Did you check this filter? More pics in the link.
    http://www.advrider.com/forums/showpost.php?p=17527454&postcount=52

    [​IMG]

    Do you have a stock tank and vacuum petcock? If so, take the fuel line off at the carb. With the engine off and the petcock on 'ON', no fuel should flow. On 'RES" no fuel should flow. On 'PRI' there should be a good fuel flow.

    Posting pics for a visual, since we can't be there, guessing on a stock, vacuum petcock. The stock petcock can also be used on the IMS fuel tank and on the new Acerbis.

    When 'ON' no fuel should flow: (engine off) Note: this is NOT 'RES', it is 'ON'.
    [​IMG]

    There should be a good stream of fuel when switched to PRI, engine on or off. Since you had the carb off, your float bowl is empty. You have to put it on 'PRI' in order to fill the float bowl so the bike can start.
    [​IMG]

    When switched to 'RES' there should be no fuel flow with engine off.
    [​IMG]

    This is the pilot jet, a very small orfice, did you look through it?
    [​IMG]
    #20