• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Suzuki DS 80 Wont Run Properly

icebergstu

icebergstu

Husqvarna
AA Class
84 Suzuki DS80 2T Air Cooled Mini Bike. Owned for 5 years and ridden hundreds of times by my son over the last 5 years without issue.

HISTORY - FULL REBUILD BY EXPERT MECHANIC (Not Me) 5 rides ago.

Wont Idle or run unless at High RPM. You have to keep pumping the throttle to keep it going. Starts fine on the throttle.

What I have tried so far:

Tried running without air cleaner - no change
Changed the plug for a brand new one - no change
Pulled the Carbie off
Completely dismantled the carb down to everything but the butterfly, pulled nozzle, main, pilot, air mix, idle out and took all breathers off.
Used liberal amounts of CRC Carbie Cleaner throughout and compressed air.
Cleaned out the Tank and petcock - Good flow
Carefully re-assembled Carb
Re-installed carb
Kicked bike over and it started
Same problem.......Symptoms of a blocked primary.

It bogs then revs right up on the throttle but then seems to starve of fuel....

Pulled carb off again and changed float level, checked primary and main jet. All clean.
Re-installed Carb
Same issue, no change whatsoever????

Is there any way it could be electrical?

Your expert advice would be appreciated!

Stu
 
sounds like an air leak... try to check it by using degreaser (brake cleaner)- spray it onto the intake rubber boot oder the base gasket and see if the engine does run different.
 
I had the same problem with a JR 80, it would bog or rev but never really run right no matter what I tried. Thankfully the grand kid out grew it and I sold it.
 
I tend to agree with air leak. Old whipper snipper did exact same thing itd start but you'd have to rev it's tits off to keep it goin or it sounded like it ran outta fuel. immediately went for plug/carb/fuel/exhaust issues then after an hour of head scratching saw one of the cylinder base nuts was loose & she was suckin air
 
Could the pilot jet have a little buildup that's not easily visible? Is the o ring for the intake flange in good condition? Possibly grease the o ring upon install. Bad o ring on the idle adjustment screw causing an air leak?
 
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