'04 DL650 dying in gear and in neutral, help! - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 30 Old 06-26-2018, 09:50 AM Thread Starter
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'04 DL650 dying in gear and in neutral, help!

Hello everyone!

Let me start off by saying how awesome this forum is and how incredibly helpful so many of you have already been in my short time owning this bike.

I'm a new owner of a 2004 DL650 that I got for dirt cheap with a few issues. I saved enough on the purchase that I did not mind replacing parts to get her up to speed. In no particular order I got: New tires, new OEM fuel pump assembly (tried the external fuel filter before splurging), iridium spark plugs, air filter, oil + filter, chain + sprockets, clutch lever, and battery.

I did everything myself (except for tires) thanks to your guyses help, but it appears I'm stuck on my most recent issue.

Here's the issue: When the bike is warmed up, coming to a stop or while stopped, the bike will 'skip a beat' (engine miss?) where it'll go completely silent for a split second, revs will drop, and then continue running. This will happen a few times if I do not give it some throttle and eventually will die without intervention. It's worth noting this happens whether I'm in gear with clutch in or even in neutral. (I thought it was a clutch issue so I adjusted it today but issue is still there)

Now here's where it gets tricky: When I press the starter button to start it up again, with the clutch fully in, nothing happens. Now if I keep the starter pressed and let go of the clutch very slightly it will start right up. My clutch switch is a bit dodgy (bent pin) bit it's still there and always lets me start her up without fiddling with it.

I have no idea what it could be as I've read conflicting info all over the place. I don't think it's bad gas as I only fill up at top-tier stations and always use premium. I've also ran it on 1 bar for a bit (so close to empty) and did not have any fuel delivery issues (or water intake issues).


Any help would be much appreciated! Here's a pic on the way to the shop with tires and my secondary mode of transportation
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post #2 of 30 Old 06-26-2018, 07:34 PM
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What brand of clutch lever did you buy? Aftermarket ones can have problems engaging the clutch safety switch. The "tricky" part of your issues sounds like a bad clutch switch as in corroded and not making good contact.
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post #3 of 30 Old 06-26-2018, 07:42 PM
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Quote:
clutch lever,
Yup - it's either the switch or the lever has no tang on it to push the switch in ....guess how I know.

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post #4 of 30 Old 06-26-2018, 09:08 PM
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I have the "gets tricky" part. Just started before I got home from the Eastern Rally. Pull in the lever all the way against the grips, no start. Release the lever slightly, maybe a quarter inch, and it starts. Sometimes I have wiggle the lever back and forth slightly a hair or two and then it starts. But it has always started if I use that process. And I do have aftermarket cheap Chinese knock-off levers but have had them on the bike for five (5) years. My guess is it is my switch, probably worn or corroded, but haven't had time to pull off and check.

I do not have "the issue". I do not see any deviation in rpms stopped, stopping, or otherwise.
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post #5 of 30 Old 06-27-2018, 09:21 AM Thread Starter
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[QUOTE=Macdoc;5271115]Yup - it's either the switch or the lever has no tang on it to push the switch in ....guess how I know.

I bought the MZS Shorty Levers off Amazon.

The lever may be the cause of the secondary issue, but I don't think it's what's causing the bike to die while running in neutral...Right? As far as I know the clutch switch only prevents the bike from starting if not depressed, it won't kill it while running.
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post #6 of 30 Old 06-27-2018, 09:47 AM
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Running issues at low throttle are often associated with a worn TPS. Google here and search for TPS issues, there will be a ton of references. I have no personal experience with that issue.

Would help if you provide more details about your bike, mileage etc.

Other possibilities are loose battery connection or poor/ corroded contacts or corroded ground contacts of the main electrical system. Worth checking regardless as preventative maintenance. Also check the main connector in the left front fairing to make sure there is good clean contact and no signs of burning.

Others may have more specific experience to chime in.

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post #7 of 30 Old 06-27-2018, 11:44 AM Thread Starter
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It's an '04 DL650 22k miles. Bought from a guy in Orlando (Im in Miami) who left it sitting for a while in the elements after the hurricane destroyed the shed it was in. I managed to ride it back to Miami (not the best idea) all the while I was experiencing fuel delivery issues consistent with a clogged fuel filter. About a month and $1k later she has all the new important bits and was running fine for a few hundred miles. I took her on a few dirt roads with some mud puddles here and there and started experiencing this issue shortly after.

I just put her in dealer mode and am not getting any codes while I am experiencing the same cutoff issue. Now it is happening while cold, can't even let the bike warm up for 30 seconds without it dying. I notice that it idles at around 1100rpm then slooooowly comes down to 1kish and starts to cut off.

Also worth noting: She runs fine as long as she's moving. I get the cutoff issue when I am coming to a stop traveling <10mph with clutch in in 1st gear and also while stopped. I can keep her alive with some throttle input.

I checked the battery connection and switched the battery with a lithium in my other bike ('01 SV650 for sale!) and don't notice any difference. It still dies. Will try adjusting my idle up.

I'll order the TPS as that seems like my best bet, unless somebody has any other ideas for me to test before I dig myself deeper in the hole?
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post #8 of 30 Old 06-27-2018, 04:06 PM
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Your mileage seems low for a TPS been worn out. Raise the idle to 1300 first and see if it helps.

Check for corroded electrical connectors, especially if riding through puddles may really be correlated with the problem. May be coincidence, maybe not.
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post #9 of 30 Old 06-28-2018, 07:44 AM
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+1 for too low idle speed plus maybe corroded electrical connectors. Have a look at https://www.stromtrooper.com/dl650-d...dying-tps.html.
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post #10 of 30 Old 06-28-2018, 08:07 AM Thread Starter
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Admin is taking too long to approve my messages so I'll just write it again...

Mistakenly raised RPM's to 3k, it still dies (I got it down to 1500 now). Checked fuel pump - I nearly filled up a plastic water bottle (500ml) with 3 priming cycles. Checked spark plugs, they seem fine and have a nice brown color on tip. Checked air filter and gasket, still looks new. Electrical connections look good from what I can see..
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