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Discussion Starter · #1 · (Edited)
Updated...more help: what did I do....bike refuses to run

So here is what I did on Saturday to my 2003 dl 1000 with 78,000 miles:
*new battery
*new plugs
*cleaned the k and n filter and oiled it
I put everything back together and ran the bike up the road for 5 minutes with zero issues. Then i pulled into the garage and the bike stalled, I restarted it but it kept trying to die, blipping the throttle causes it to hang at 3000 rpm and then it slowly drops until it dies again. Running the bike at 4000rpm causes it to surge like mad, sputter, pre-fire and back fire. If you put the bike in gear it refuses to run. I've checked the throttle sync, the tps setting, the tightness of the boots, checked and rechecked all the vacuum lines. Without the airbox in place it runs slightly better but still sucks and even removed the secondaries with low hopes of change and of course no change. I've cleaned the throttle bodies, ran seafoam through them and still nothing.
I'm thinking about replacing the tp sensor and if that doesn't work then throwing it in the trailer and off to the shop for the first time ever!
Thoughts?
 

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After running at a steady speed, some have experienced the same issues you described, including myself. Some feel it is the TPS not sending the correct signals. Twist your throttle full open and closed a few times and see if anything improves. The R1 forum has had a few issues as well, and suggest taking the TPS off and cleaning with contact cleaner. If mine gets any worse, that is the direction I am going.
 

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Discussion Starter · #3 ·
throttle

I forgot to mention I tried the throttle wide open blip more than a few times with the key on but not running.....it seemed to start better but continued to complain and moan. Tomorrow I will try your suggestion of cleaning the tps...I also plan on dumping the gas even though I'm 4 gallons into it with no problems until now.
Thanks!
 

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I would start by reversing the things you swapped out. A bad battery can cause strange things to happen. Do you still have the old battery?

Pull the plugs and see if something odd is happening. Not seated right? Cracked? Not gapped correctly, wrong plugs?

If it was working fine before, it must be something you wiggled while in there.

That would be my first guess.
 

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Sounds like a fuel problem. Is the pump running, sound right? By removing the tank, are the vent hose installed correct. Open the gas cap. this allows the tank to vent. Filter pluged? Do a fuel flow test.
 

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So here is what I did on Saturday to my 2003 dl 1000 with 78,000 miles:

*cleaned the k and n filter and oiled it

Thoughts?
Start with what you did first. I would look closer at the air filter. Maybe the oil is too thick and not allowing air to pass.

That's where I would start. Good luck!

.....
 

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Oh i missed the part about the K&N filter. THATS your problem. If you try to ride the bike without letting the newly oiled filter sit overnight, there isnt enough air getting into the engine and you foul your plugs. Pull/Clean the plugs and your GTG.

DAMHIK
 

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Discussion Starter · #11 ·
my work continues.....

So I did a flow test on the fuel pump and it failed but only slightly....
I pulled the pump and cleaned the low pressure screen which I would say was around 25% blocked and while I was at it I performed the fuel pump filter bypass which can be found here: External Fuel Filter modification
Did the bike need it? I don't know but I'm creeping up on 80K and I figured since I was in this deep I might as well.
The fuel pump doesn't have a high pitch whine anymore and sounds less stressed.

So the bike when fully assembled is still complaining some but not as much and here is a BIG CLUE but I still need advice:
When I unplug the vacuum line from the intake air pressure sensor....which leads to the throttle body.....the bike runs almost perfect.....according to the manual "the sensor detects the intake air pressure, which is then converted into a voltage signal and sent to the ECM". So do I replace the IAP Sensor????

Thanks so much!
 

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my money is on the air filter............
 

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The no air through the KN is silly but the machine suckying in a boat load of oil and wetting down the plug is possible.

If she's running make no judgements till you have a tankful of gas through it.

If you put back the old gas wait till 1/2 way through next tank.

Then try a good does of

SEAFOAM

If that don't do it then think further
 

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Discussion Starter · #14 ·
Air

I've eliminated the air filter being an issue by running it without the air box on...I even ran it with the air box in place and no filter...so I'm still a little stumped. My plan is to talk to a shop today about the IAP issue...vacuum hose on, bike is a pain, vacuum hose off and the bike runs great....but there is a safety issue there, sometimes the idle will hang high when that hose is off. Since the hose leads right to the second throttle body the issue could still be the TP sensor......which I never removed for cleaning thanks to the security torx bits that is on it. Suzuki either doesn't want you to remove it or they are afraid someone might steal it. I have a set of security bits here at work that I plan on taking home tonight so I can accomplish this task.

Thanks again!
 

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I took both vacuum ports and connected them with a hose

Mine is NOS and to get it to run I needed NEW plugs. Old ones appeared OK but no go.

Put in Iridiums because that's what I like a she fired right up
 

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I don't believe you can run a bike with the air filter off. It needs some back pressure to run properly.

Did you ever look at your spark plugs? Once they are carbon fouled your bike will run like crap until you clean/replace them.
 

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The bike will run with no air filter. It will just be a bit lean.
 
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