Sputtering and sluggish - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 16 Old 03-22-2019, 09:06 PM Thread Starter
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Sputtering and sluggish

So the new to me 2016 dl650xt really sputtered home tonight. Iím still in the break in period so itís hard to open it up but there is no full throttle response. Bought as new old stock by 1st owner in 2018. I just got it with 240 miles last month. He obviously didnít ride. Do I have condensation water in the tank, ethanol sludge, or something Iím missing? I know better and should have dumped his old tank before even riding but forgot all about the joys of ethanol and/or water. Do I dump tank? Is there a fuel filter? Thanks in advance.
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post #2 of 16 Old 03-22-2019, 09:21 PM
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Ö Do I have condensation water in the tank, ethanol sludge, ...

well maybe all of the above ?? I would start with fresh gas for sure. Whilst you dump the tank check if there is corrosion (rust) inside. If yes remove the pump and clean and treat the rust. If no just add new gas and see if that fixes things. If still rough I would try some injector cleaner which will hopefully dissolve whatever is causing the problem.

Yes the pump has a mesh pre-filter and a high pressure secondary fine filter. That one tends to plug up at higher mileage but I doubt that this is your problem, too few miles.

Keep us posted what you find. There will be more and better comments if you can provide more detailed description of the symptoms your bike has.

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post #3 of 16 Old 03-22-2019, 09:26 PM Thread Starter
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Originally Posted by blaustrom View Post
… Do I have condensation water in the tank, ethanol sludge, ...

well maybe all of the above ?? I would start with fresh gas for sure. Whilst you dump the tank check if there is corrosion (rust) inside. If yes remove the pump and clean and treat the rust. If no just add new gas and see if that fixes things. If still rough I would try some injector cleaner which will hopefully dissolve whatever is causing the problem.

Yes the pump has a mesh pre-filter and a high pressure secondary fine filter. That one tends to plug up at higher mileage but I doubt that this is your problem, too few miles.

Keep us posted what you find. There will be more and better comments if you can provide more detailed description of the symptoms your bike has.
Rust on the filler cap dang it. Didn’t notice it on the fill up. Obviously can wire brush the rust but any preventative after that.

Just no power at 5k and really sputtering and straining to get past there. Never stalled or anything.

Last edited by Dwighop; 03-22-2019 at 09:28 PM.
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post #4 of 16 Old 03-22-2019, 09:40 PM
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Well if its not revving beyond 5k but reasonable below, it could be the filter. At least that is the typical scenario.

Clean that tank, take the pump out and see what's going on. Don't run it any more, will make it worse if there is a lot of crud in the tank.

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post #5 of 16 Old 03-22-2019, 11:47 PM Thread Starter
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Originally Posted by blaustrom View Post
Well if its not revving beyond 5k but reasonable below, it could be the filter. At least that is the typical scenario.

Clean that tank, take the pump out and see what's going on. Don't run it any more, will make it worse if there is a lot of crud in the tank.
Doesn’t look to be dirty just looking inside. Will siphoning gas pickup any crud since it might be too heavy to come up? I just can’t believe there is any crud. I want to lean toward Seafoam and some water removal. (Cause pulling the pump out doesn’t sound fun to me)

I don’t think Seafoam would have helped.

What needs to be replaced and what needs to just be cleaned. Obviously a new mesh filter. Maybe the regulator? New aftermarket fuel pump to mod the high pass filter. (Link for high pass filter mod appreciated)

Method for treating rust in the tank?
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Last edited by Dwighop; 03-23-2019 at 09:00 AM.
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post #6 of 16 Old 03-23-2019, 12:13 PM
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Man this is a real bummer. Had this bike been parked outside in the rain?

I suspect the tank is really bad and maybe best to replace it Ö and the pump is shot, at least the filters need to be replaced.

I would search e-bay and see if there is a used tank somewhere.

Threating rust in thank, I did one years ago on a 82 Honda, a lot of work but in the end successful. You need to do google search here and in general. There will be lots of information. Others may comment with more recent treatment procedures.

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post #7 of 16 Old 03-23-2019, 12:36 PM
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My lazy approach in this case would be to bypass the internal fuel filter with an external automotive one, flush the tank and as long as it's not leaking just ride it a bunch. If it's mostly surface rust, you might get lucky and it could clean up. The bike is only three years old after all, the rust should not be deep.

You should also check the tank vent / drain hoses, particularly the one for the filler cap ring area - sounds like it got plugged and let a ton of water in.
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post #8 of 16 Old 03-23-2019, 01:44 PM
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Doesn't look good.
Look in the tank from the where the pump is. The tank tends to rust more in the upper part.
Clean the pump as much as you can, but looking at the picture of it might be past the salvage point.

When you put the pump back in, do a simple fuel flow test.
Disconnect the fuel line from the pump, put in a piece of plastic pipe and use a measuring cup.
Do 3 full ignition on-off cycles.
With a fuel pump in good condition you should get around 3-3.5dcl of fuel out.
Down to about 1.5dcl the engine will run ok.

My tank had rust in it, and the high pressure filter was clogged.
I did a bypass with a external fuel filter and it was ok, but when the tank starts rusting it will only get worse.

The fuel pump assembly is different in newer models, and don't know if a external filter modification can be done.

Used a POR15 tank liner kit, and it came out really good.


I need a few more post and then I can link pictures, and as soon as I can I will post the process with POR15.



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post #9 of 16 Old 03-23-2019, 02:52 PM Thread Starter
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Doesn't look good.
Look in the tank from the where the pump is. The tank tends to rust more in the upper part.
Clean the pump as much as you can, but looking at the picture of it might be past the salvage point.

When you put the pump back in, do a simple fuel flow test.
Disconnect the fuel line from the pump, put in a piece of plastic pipe and use a measuring cup.
Do 3 full ignition on-off cycles.
With a fuel pump in good condition you should get around 3-3.5dcl of fuel out.
Down to about 1.5dcl the engine will run ok.

My tank had rust in it, and the high pressure filter was clogged.
I did a bypass with a external fuel filter and it was ok, but when the tank starts rusting it will only get worse.

The fuel pump assembly is different in newer models, and don't know if a external filter modification can be done.

Used a POR15 tank liner kit, and it came out really good.


I need a few more post and then I can link pictures, and as soon as I can I will post the process with POR15.



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Iíve ordered a new fuel pump since I pretty sure the internal filter is going to be pretty dirty too. Unless a smoking hot deal comes along for a new/used tank I just going to try and clean it.
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post #10 of 16 Old 03-23-2019, 06:07 PM
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This works on old Coleman lantern tanks: Drop in a handful of copper plated BB's, then a little Kerosene and shake for about 5 min. Drain out BB's, flush with water until clear, then dump in some alcohol and shake that for a few to remove all water from inside of tank, then dump the alcohol out.

For our tanks I would use a whole carton of BB's & since your tank is pretty nasty you might want to rinse and repeat. Just make sure you get all the BB's back out. Once clean, I would inspect the inside with a light and mirror. If it's pitted, I would do what Jeeves did with the POR15.

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