Possible Carb Problem?

jimowen

Cadet
Joined
Jul 11, 2003
Messages
10
In an earlier post, I told of my troubles with a '95 model DT115. It doesn't get full rpm under load. Originally, I thought (still do) that the problem is related to the CDI unit (via throttle position switch) not allowing full spark advance. It only gets 3000rpm under load, but will do 6K in neutral.<br /><br />A couple of you folks (Thanks!) posted that they thought it was probably gummy carbs, so I spent all day today trying to use spray cleaner on them, as well as run 5 gals of clean fuel and carb cleaner mixed. No Change in performance.<br /><br />Another thought just occured to me. If there is a restriction or faulty fuel pump, could that cause a limited high rpm? (runs smoothly, just slow under load)<br /><br />I would think that a lean fuel mix would cause erratic engine performance (that's why I discounted fuel problems in the beginning).<br /><br />Questions:<br />1. If the fuel pump couldn't "keep up" with needs, would it limit top rpm (yes) while engine still runs smoothly?<br />2. Barring buying an in-line pressure gauge - is there a simple test to ensure pressure/flow is sufficient?<br />3. Any other ideas? (I'm trying everything to avoid buying the CDI unit @ $1K)<br /><br />regards,<br />Jim :confused:
 

JB

Honorary Moderator Emeritus
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Mar 25, 2001
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45,907
Re: Possible Carb Problem?

Hi, Jim.<br /><br />Gummy carbs need to be dismantled and soaked, not sprayed.<br /><br />Good luck.
 

fish4970

Petty Officer 2nd Class
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Mar 11, 2003
Messages
105
Re: Possible Carb Problem?

I think JB nailed it.<br /><br />i use a product called chem-dip<br />that can be found at many auto parts stores<br />Be carefull with plastic or ruber parts<br />it will melt them
 

jimowen

Cadet
Joined
Jul 11, 2003
Messages
10
Re: Possible Carb Problem?

I pulled the carbs, disassembled, cleaned, etc. Found a tiny bit of water and dirt, but nothing extreme. Reassembled everything and it idles a bit smoother, but still only 3000rpm under load. Even sprayed starting fluid into carbs at full speed (no increase in rpm)... I'm back to thinking the CDI unit is at fault. I did notice an obscure sentence in an old manual that says "due to high inductance of L1 at high speed, capacitor charging is done at high speed by L2 only..." (or similar wording) There's also that "Over-rev module" inside the CDI. Everything is very smooth (just slow). All cylinders are producing power. Compression is 125-130. I don't have a timing light, but the ignition is all "bolt-on" with no adjustments. Primer bulb is hard. etc <br /><br />Still stumped,<br />Jim
 

JB

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45,907
Re: Possible Carb Problem?

Sounds like you had more than one problem, Jim.<br /><br />Seems that you have solved the carb part.<br /><br />Seems that your remaining problem could be:<br /><br />1. Failure to advance ignition timing fully when throttles are opened WOT. "Retarded" ignition produces very smooth operation but really reduces power.<br /><br />2. Rev limiter intervention. Don't know how this works on your Yammy.<br /><br />I would carefully compare throttle linkage and ignition synchronization to the Manual, then hope a Yammy-spert comes along to address the rev limiter question.<br /><br />Good luck. :)
 

jim dozier

Lieutenant Commander
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Jan 8, 2003
Messages
1,970
Re: Possible Carb Problem?

I am assuming that the DT115 is a Suzuki and yes if you have insufficient oil flow some Suzukis (your manual will tell you if yours does) kick on a rev limiter at about 3000 rpm. There may be a reset button on the ignition module. At any rate you need to check<br />1. Oil level in the tank and discharge outlet.<br />2. Hoses from tank to oil pump and oil pump to engine for crimping or obstructions.<br />3. Oil filter for clogging.
 

jimowen

Cadet
Joined
Jul 11, 2003
Messages
10
Re: Possible Carb Problem?

FIXED IT!!!! Now that I've rebuilt the carbs, cleaned everything, wiggled everything and it still didn't work... I returned to basics (for the third time)<br /><br />The local tech said to disconnect all the sensors, if that fixed it, that sensor was at fault. Well, I knew the throttle position switch was bad (incorrect voltages), but removing it didn't fix the problem. So, I got creative and SHORTED the two wires...Voila! Ran like a scalded ape! Took it out for a quick spin and was registering 46 mph (gps). Thanks for everybody's help! (New part is ordered)
 

JB

Honorary Moderator Emeritus
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Mar 25, 2001
Messages
45,907
Re: Possible Carb Problem?

Good news, Jim!<br /><br />I know that a DT115 is a Suzi. I guess my brain was infected with the Yamavirus. :rolleyes:
 
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