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Old 05-29-2013, 07:27 AM   #14566
p3dro
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the saga continues...

1 month to the day, and the garage I use are still struggling to get her started.
Replacement CDI and re-wound Generator fitted - still no spark!

Can anybody recommend a garage / mechanic in the South East of England proficient with DR800 electrics?
If my garage cannot find the fault, we are going to have to have a very difficult conversation and I'm going to have to get the bike fixed elsewhere (I hope!)

I tried a recommended Suzuki Dealership nearby that specialises in ATV & Offroad bikes and was told that because it is an import, they would not touch it! THANKS SUZUKI!!

If I had the tools, a garage, and some time, I would try myself, but I have no idea about electrics, let alone the rest of the above!!

I really don't want to sell her as a non-starter...

P
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Old 05-29-2013, 10:35 AM   #14567
Bambi
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Hello P,
do you know if the 'trigger' works? The cables, leaving the engine case from the generator often get caught between the mating surfaces. The fact, that the generator sits in the hot engine-oil is another drawback. This may help keeping it cool but it causes the wires to get harder and thus they are prone to break. On my 750, this 'trigger' is mounted to the stator-ring via a connection, that, because of it's form would be called a 'swallow's-tail' by a German joiner. This connection had worked loose on my bike and those hardened wires broke off. So no sparks!
I'm sorry, I'm off for our annual Big-meeting tomorrow morning. If the problem's not solved at the start of next week I'll try to get you the correct readings of resistance and so on in the electric circle of your ignition. Hopefully, I expressed myself understandable as I'm an electric-noob even in my German mother-language ...
Keep on going, kind regards, Bambi
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Old 05-29-2013, 10:40 AM   #14568
Bambi
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Sorry P,
I didn't pay enough attention to your first sentence, so my thoughts should be too late.
There's a lot of switches on these bikes, side-stand, clutch, decompression. Have they been tested?
Regards, Bambi
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Old 05-29-2013, 12:35 PM   #14569
Geo-Nemesis
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ANY IDEA about that sound? what can be the problem?

http://www.youtube.com/watch?v=iKT8mMIzfyc

thanks to all
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Old 05-29-2013, 06:14 PM   #14570
Ladder106
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I'd have a look at valve clearances first. Sounds are really hard to diagnose over the net.

Lets start with year, model and any modifications.

Did the sound start suddenly or has it been getting louder over the past 1000 miles or so?

To my ear, it sounds like something in the upper end. Not a "deep" enough knock to be connecting rod or lower end bits.
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Old 05-29-2013, 06:16 PM   #14571
ausibatla
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[QUOTE=p3dro;21516291]1 month to the day, and the garage I use are still struggling to get her started.
Replacement CDI and re-wound Generator fitted - still no spark!

p3dro

If I was you I'd get it out of their workshop. Put it on a trailer and take it home until you find someone who can fix it. The mob who are working on it are obviously bloody useless, to put it mildly. If they haven't sorted it in a month they aren't going to. Whats more it could be something simple, like a broken wire in the loom. If they tested each wire they would find it. Assuming of course that this bunch of clowns possess a tester.
Have you posted the problem on DrBig info. There may be someone close to you who can help.
The other bunch who won't touch it because it's an import have only told you that because they are probably as useless as the clowns who are stuffing you around now.
I hope you get it sorted.
Cheers.
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Old 05-30-2013, 02:11 AM   #14572
p3dro
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Thanks Bamabi,
I'm going to get a full list of the things the garage say they have tested this weekend to try and eliminate a few causes!

Thanks Ausibatla,
Personally I agree with you, but it's so hard finding a decent mechanic around here who is willing to take on a bit of responsibility. I'm going to see them on the weekend so will have it out with them then.
I posted a message on DrBig.info too - hopefully there's someone around!

Cheers,
P
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Old 05-30-2013, 06:55 AM   #14573
robmoto
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Quote:
Originally Posted by Geo-Nemesis View Post
ANY IDEA about that sound? what can be the problem?

http://www.youtube.com/watch?v=iKT8mMIzfyc

thanks to all
Does the noise stop when hot. how many klm,s on the bike.
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Old 05-30-2013, 09:16 AM   #14574
Geo-Nemesis
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Quote:
Originally Posted by robmoto View Post
Does the noise stop when hot. how many klm,s on the bike.
sound like this only when cold, the bike has 61000 kms


Quote:
Originally Posted by Ladder106 View Post
I'd have a look at valve clearances first. Sounds are really hard to diagnose over the net.

Lets start with year, model and any modifications.

Did the sound start suddenly or has it been getting louder over the past 1000 miles or so?

To my ear, it sounds like something in the upper end. Not a "deep" enough knock to be connecting rod or lower end bits.
it is an '89 sr41 a and I am not sure, but looks a very little more louder then "before" (this autumn)
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Old 05-30-2013, 10:29 PM   #14575
Ladder106
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Quote:
1 month to the day, and the garage I use are still struggling to get her started.
Replacement CDI and re-wound Generator fitted - still no spark!
......and are they still lighting the place with oil lamps?

Maybe they're in an electron free zone
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Old 05-30-2013, 11:10 PM   #14576
robmoto
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piston slap perhaps

Quote:
Originally Posted by Geo-Nemesis View Post
sound like this only when cold, the bike has 61000 kms

Hate to tell you but it could be piston slap, I had a sr/41 and it would make the noise only when cold but it had done 140k when warm and hot no noise at all and did not blow smoke, put a new oversize piston and rebore to suit .
60k on the clock there should be hardly any wear in the bore and piston so it may have had a hard life.......




it is an '89 sr41 a and I am not sure, but looks a very little more louder then "before" (this autumn)
.......
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Old 05-30-2013, 11:58 PM   #14577
bluesman
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Quote:
Originally Posted by Geo-Nemesis View Post
ANY IDEA about that sound? what can be the problem?

http://www.youtube.com/watch?v=iKT8mMIzfyc

thanks to all
Did you check usual suspects? Just to go by the book?
Balancer chain? Cam chain tensioner? Clearance on decompressor shaft?

61000 km is more than enough to have wear on piston, rings and bore beyond service limits. But not catastrophic. If it does not take lots of oil - then forget about that. But if previous owner did run it too hot or too "dry on oil" once - it can be bad already.
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Old 05-31-2013, 12:17 AM   #14578
jimbobthebear
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Hi P3dro

I had a similar problem that turned out to be the run/stop switch contacts. worth a quick check.

I havent read back far so if you've already looked at this, apologies.


Cheers
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Old 05-31-2013, 01:16 AM   #14579
Geo-Nemesis
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Quote:
Originally Posted by bluesman View Post
Did you check usual suspects? Just to go by the book?
Balancer chain? Cam chain tensioner? Clearance on decompressor shaft?

61000 km is more than enough to have wear on piston, rings and bore beyond service limits. But not catastrophic. If it does not take lots of oil - then forget about that. But if previous owner did run it too hot or too "dry on oil" once - it can be bad already.
Both chains looks fine (checked last sunday)
-Clearence on decomp shaft- I have no idea what is that and what should be, can you explain me?

The bike doesn't smokes, It does not eat lot of oil (didn't notice any resonable oil missing)
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Old 05-31-2013, 02:27 AM   #14580
p3dro
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Quote:
Originally Posted by jimbobthebear View Post
Hi P3dro

I had a similar problem that turned out to be the run/stop switch contacts. worth a quick check.

I havent read back far so if you've already looked at this, apologies.


Cheers
Thanks Jim, I'm a total novice with electrics so could you please tell me where that would be to check? I'm guessing the 'kill' switch on the throttle controls? I'm going to ask the garage what they have checked this weekend and discuss how much they want to charge me...

Cheers,
P
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