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Help on Suzuki DR650 weak spark, MXTuner?.. or zuki owners

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Zodran

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Dec 2, 2003, 9:15:25 PM12/2/03
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Trying to do some long distance troubleshooting on my buddy's 96 dr650. This is
a bike I found for him several years ago and he bought as salvage from a
dealership fire. Other than a melted mirror and turn signal and lots of elbow
grease it cleaned up perfect and has been troublefree.
The problem he is having is it starts and idles fine, under acceleration it
falls on its face. He has had the tank off, carb off and disassembled and has
eliminated a fuel related problem with reasonable certainty. He got a inline
spark analyzer and said at idle it's got a fat blue spark, but give it some
throttle and it turns yellow and weak looking. It's got two spark plugs as I
recall but don't think that's relevant.
Does that sound like a coil problem or the CDI or something else? Can the coil
be tested accurately before he buys a CDI or could it be the stator. He has a
manual but I'm not sure what the procedure is, also thinking that it's likely
related to it's history of surviving the fire. A few years ago on my
dreamsickle xrl I went thru all the procedures in the service manual and
eliminated all other possiblilities, and not having a known good CDI to test
with got one for $150. Any ideas would be much appreciated, we didn't get to
make our annual colorado trip this year due to his wife's surgery, the pussy.
I'd like to make sure we smooth any snags for planning next year's trip, and
wouldn't want to see him buy something he didn't need. I think there's a guy we
kind of know from FSSNOC that would be fairly close to him that might still
ride the same model, just hate to have to ask for that kind of a favor, yet!
Thanks in advance, Dean K.

spodely

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Dec 2, 2003, 9:23:01 PM12/2/03
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I may not be much help, but I have had the same problems on both a Yamaha
and a Suzuki. Without the electronic testing equipment to use, I just
started cheap and worked my way up. I started with new plugs, then the
coil. Both bikes ended up needing the coil replaced. One was a combination
of dry, cracked and peeling coil wire and cap, the other was the coil
itself.

I would check the ground to the coil also. The RMX I bought last year had
some rust under the coil where it grounded and also caused intermittent
problems.

Good luck,
John


Craig Faison

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Dec 2, 2003, 10:52:22 PM12/2/03
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On 3 Dec 2003, Zodran wrote:

> Trying to do some long distance troubleshooting on my buddy's 96
> dr650. This is

Where is he located? I know of a DR650 in DE who's owner wouldn't mind
swapping parts around to test...

Craig

Zodran

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Dec 3, 2003, 7:23:35 PM12/3/03
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Thanks John and Craig for your replies, we're around kansas city, my buddy's
over on the kansas side. I doubt it's a corrosion problem, he has lived with
triumphs so is a bit anal about checking and cleaning connections.
I'll have him bring his service manual to work tomorrow so I can get a feel
for the procedure on his bike. The DR650 is a rare animal in comparison to
hondas around here, just wanted to see if anyone else was having a similar
problem with one.
Thanks again, Dean

David Kelly

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Dec 3, 2003, 9:16:42 PM12/3/03
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On Wed, 03 Dec 2003 02:15:25 +0000, Zodran wrote:

> The problem he is having is it starts and idles fine, under
> acceleration it
> falls on its face. He has had the tank off, carb off and disassembled
> and has eliminated a fuel related problem with reasonable certainty.

Has a CV carburetor I believe? Before throwing bucks at the thing I
recommend another very close look at the vacuum throttle slide and
diaphragm. A leak in the diaphragm or top cap will prevent the engine from
revving yet run perfectly at idle.

> He
> got a inline spark analyzer and said at idle it's got a fat blue spark,
> but give it some throttle and it turns yellow and weak looking.

Unless he has used that same tool on the same model bike and gotten
different results, I wouldn't totally trust it. At the least try it on a
known good bike (yours?) of different model.

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