David Offor
Registered
Hello again all.
I wish I could say I'm new to the site but unfortunately, I still haven't got to the bottom of my bikes running problem.
This is my 6th thread (5 too many).
First problem-: The bike is fouling no. 2 and 3 plugs, when the throttle is opened from tick, over upto 3000rpm, it feels like its running rich, once it gets past 3000, the rev counter needle flicks up fast and feels like other cylinders have kicked in, that's the low rpm problem.
Second problem-: In about 3rd gear with the throttle pinned back the bike gets to about 9000rpm, then starts stuttering/holding back (feels like lots of misfires) it brings up C26, misfire on no.3, I also managed to get C25 too, misfire on no.2).
The bike feels underpowered, it won't lift the front on the throttle, which I know it should, I only weigh 11.5stone 76kg.
Ok, things I've tested and changed (deep breath)-:
New timing chain (today)
Timing marks are now lining up better
Cam chain tensioner has had the mod done
New fuel pump (holding 43psi during priming, cranking and accelerating upto 5000rpm)
New temp sensor
New cam position sensor
New plugs
New injector filters/shields
Checked that all injectors are squirting same distance
New piston rings fitted (ring gaps all fall within book spec)
Head and cylinder section, skimmed and checked
New .40 cometic headgasket, allowing/compensating for skimming work
All valve clearances are within book spec
Compressions done, all 4 cylinders are 175psi (checked again today)
Leak down test, holding same pressure across all cylinders (checked again today)
Tried another wiring loom/harness
Tried another TPS (set up in dealer mode -00)
Synced throttle bodies (various times)
Running with standard Suzuki exhausts (also tried with race cans)
Tried another side stand switch
Tried another ECU
Tried another rectifier
Tried another gear position sensor
Tried 2 other 'boost' sensors (IAPS)
Tried 3 sets of coils (second hand coils)
No power commander fitted
No alarm on the bike
I've been told that setting up the TPS on the bikes dashboard isn't accurate enough and it's position is critical, by a Suzuki technician, he said that it would make the bike misbehave at high rpm, if it was not exactly in the right position, can anyone confirm this?
I haven't been able to change my crankshaft sensor, could a faulty ckps cause my running problems?
I haven't changed my injectors but have swapped cylinder no. 3 to no. 4 but still it brings up no. 3 misfire, so I thought that this would eliminate a faulty injector on no. 3.
I pull the coil leads off one at a time, on tickover and revs change on all cylinders but not dramatically, just enough to notice a change.
Bike is not overheating or pressurising, temp needle stays just below halfway and fan cuts in how it should.
I get no codes up until I force it up beyond 9000rpm or leave a sensor disconnected.
It consistently has issues with no. 2 and 3 cylinders.
The bike has done 40,000miles, owner had it from new (16 years, I'm the second owner), oil came out like tar on first oil change I did.
The bike had been parked up for over a year (which he neglected to tell me on picking it up), so I think it had a running problem when he sold it to me.
On removing the cylinder head the first time, we found excessive valve guide wear, this explained 3 cylinders not holding pressure on a leak down test, I sourced another head from a bike that had done 16,000miles and now leak down test checks out ok.
I've had this evasive problem for 2 years now, just want to find the problem, I'm loathed to give it to a garage because I've tried so much already.
I'm at a bit of a loss now, ive run out of ideas and things to test/replace/change.
Hope someone can offer a suggestion or two.
Dave.
I wish I could say I'm new to the site but unfortunately, I still haven't got to the bottom of my bikes running problem.
This is my 6th thread (5 too many).
First problem-: The bike is fouling no. 2 and 3 plugs, when the throttle is opened from tick, over upto 3000rpm, it feels like its running rich, once it gets past 3000, the rev counter needle flicks up fast and feels like other cylinders have kicked in, that's the low rpm problem.
Second problem-: In about 3rd gear with the throttle pinned back the bike gets to about 9000rpm, then starts stuttering/holding back (feels like lots of misfires) it brings up C26, misfire on no.3, I also managed to get C25 too, misfire on no.2).
The bike feels underpowered, it won't lift the front on the throttle, which I know it should, I only weigh 11.5stone 76kg.
Ok, things I've tested and changed (deep breath)-:
New timing chain (today)
Timing marks are now lining up better
Cam chain tensioner has had the mod done
New fuel pump (holding 43psi during priming, cranking and accelerating upto 5000rpm)
New temp sensor
New cam position sensor
New plugs
New injector filters/shields
Checked that all injectors are squirting same distance
New piston rings fitted (ring gaps all fall within book spec)
Head and cylinder section, skimmed and checked
New .40 cometic headgasket, allowing/compensating for skimming work
All valve clearances are within book spec
Compressions done, all 4 cylinders are 175psi (checked again today)
Leak down test, holding same pressure across all cylinders (checked again today)
Tried another wiring loom/harness
Tried another TPS (set up in dealer mode -00)
Synced throttle bodies (various times)
Running with standard Suzuki exhausts (also tried with race cans)
Tried another side stand switch
Tried another ECU
Tried another rectifier
Tried another gear position sensor
Tried 2 other 'boost' sensors (IAPS)
Tried 3 sets of coils (second hand coils)
No power commander fitted
No alarm on the bike
I've been told that setting up the TPS on the bikes dashboard isn't accurate enough and it's position is critical, by a Suzuki technician, he said that it would make the bike misbehave at high rpm, if it was not exactly in the right position, can anyone confirm this?
I haven't been able to change my crankshaft sensor, could a faulty ckps cause my running problems?
I haven't changed my injectors but have swapped cylinder no. 3 to no. 4 but still it brings up no. 3 misfire, so I thought that this would eliminate a faulty injector on no. 3.
I pull the coil leads off one at a time, on tickover and revs change on all cylinders but not dramatically, just enough to notice a change.
Bike is not overheating or pressurising, temp needle stays just below halfway and fan cuts in how it should.
I get no codes up until I force it up beyond 9000rpm or leave a sensor disconnected.
It consistently has issues with no. 2 and 3 cylinders.
The bike has done 40,000miles, owner had it from new (16 years, I'm the second owner), oil came out like tar on first oil change I did.
The bike had been parked up for over a year (which he neglected to tell me on picking it up), so I think it had a running problem when he sold it to me.
On removing the cylinder head the first time, we found excessive valve guide wear, this explained 3 cylinders not holding pressure on a leak down test, I sourced another head from a bike that had done 16,000miles and now leak down test checks out ok.
I've had this evasive problem for 2 years now, just want to find the problem, I'm loathed to give it to a garage because I've tried so much already.
I'm at a bit of a loss now, ive run out of ideas and things to test/replace/change.
Hope someone can offer a suggestion or two.
Dave.