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?
