93 suzuki dr650 crapped the bed en route to peru HELP

I'm riding my dr650 from montana to peru. made it about 2 hrs south of Portland, OR when the bike crapped out. had been running excellently until then.

here's the story:

Stopped to put on another layer, bike started, then stumbled when giving it gas at a stop light. wouldn't restart.

examined fuel/vac lines, carb jets, float valve, needle jet... no probs
examined plug: white, therefore super lean conditions (richened w. pilot
screw 1/4 turn)
examined oil level: almost dry (added more oil)
examined valve clearances (they make a lot of noise, but i set them in spec before the trip).

Intake: good. in spec.
Exhaust: OH NO! one of the clearance adjusting nuts and screws was missing from the rocker arm. Siphoned off lingering oil, found + extracted nut and screw, replaced and set to spec. LUCKY!

began reassembling carb, but couldn't get float valve assy to seat w. carb on bike. got gas in the oil due to resulting overflow.

a fellow dualsport rider stopped and helped me get the bike to his garage, where i properly reassembled (so i thought) the float valve and changed the engine oil.

didn't seat the float valve properly, got a tiny bit of gas in the oil again.

reassembled properly this time. checked for overflow with carb off bike; no overflow. reinstalled carb.

didn't change the oil this time since only a very small amount of gas got in it. started the bike up and it ran! held idle, and revved up past 5k r/min.

let it idle for about 10 minutes, but it was idling high (1700r/min) after warming up so I reduced the idle speed via the corresponding screw. engine stumbled and quit. now it won't start again. i raised idle speed back to where it was, too.

what gives? did i damage something by running it with gas in the oil?

my magneto/stator is shot too, but that hasn't been a problem so far. have a new one waiting in San Francisco, and I've been charging the battery at night so i have lights. CDI is good (tested it this morning). haven't tested ignition coil yet but i assume its still good since i got the bike to fire a couple times. I'll check it when i get off here.

anything else i should check? ill check the plugs again and see if they are wet/fouled. could running with the valve clearance essentially way too loose (valve help open) have damaged something? one would think that since it was held open it wouldn't have mangled the stem or punctured a piston. how do i check for a burnt valve? pour oil in spark plug hole and try to start, if it starts with the oil then burnt valve?
grrrr.... everything was running so smoothly too. bike was killing it on the highway, 90+ mph top speed, excellent acceleration in all gears, no weird noises.

any and all ideas are welcome

 

i doubt a LITTLE gas hurt anything
this is a 4 valve head? and all valves are in spec
de-compression lever?, the cable is adjusted
maybe you fixed the floats too god and their stuck closed now, rap the carb a few times
oil in the sparkplug hole will test the rings not the valves
the battery cant turn the starter and fire the plug, is the battery charged?
if you can get the back wheel up MAYBE you could hear a bad intake valve if you rolled the motor over while listening to the intake with the carb off, big singles are hard to turn over, this might not even work, if you can turn it over, you might not have compression
good luck

 

thanks for the response polock

4 valves, 2 intake 2 exhaust

compression is good, pretty sure valves are fine. fuel flow is good, petcock, gas cap vent all clear.

its kickstart only. no spark when kicked. decided to replace magneto since i know its a little shaky (charging coil was fried). got new part, and its ground wire has burnt out and disintegrated! no bueno. trying to get money back from ebay dude, but also thinking about splicing my good ground wire into the good magneto coil pack.

sound reasonable? i know there is no way for me to tell whether the wire burnt out due to a magneto issue or a short somewhere else in the wiring harness, but i feel like doing something feels better than doing nothing.

 

i used to have one of these, never had any problems so don't know too much about fixing one
i found the book at the end of the internet :lol:

 

here's the cdi test

 

is there any way you could do a compression test? i am not betting that this is your problem, but its totally possible that you have low compression based on the running condition you have described. compression test would help you eliminate low comp as a problem or direct your attention to it, and is easy enough to do.

 

safety switch on the side stand and a neutral safety switch

 

Hey Polock, is there one of these charts for the XJ TCIs? I thought the only test was to replace the TCI with a known good one?????

 

not in the Suzuki book
i guess if you were to measure a good one, a chart could be made
i have 3 of them, 2 known good and 1 ? maybe i'll work on that

 

If you could do that,it would be a big help to the members, especially Robert.

 

i've got the numbers, i just need to male a cute little chart for them

 

Potatoes, where are you now? Still need help?

 

still in eugene. tested coils : good.
magneto was replaced, hooray
put in new CDI box whoopee!

STILL DOESN'T ^%$#$^#@ RUN!!!

carbs i think are good, will clean them for 4th time today.
valve clearance good
have spark.
bike starts intermittently, then dies at idle. sometimes will even rev up, but then it dies at high or low rpm.

im confused.
petcock is good.
compression is assumed good because i can't budge the kickstart lever without using the decompression cable.

Maybe its an issue with the fuse box?
I feel like i will have to go thru and test continuity thru entire wiring harness at this point GRRRRRR

 

could the cam chain have jumped a tooth ?