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I need a bit of help with my DRZ. First, it's a 2005, with a big bore kit, hot cams, 3x3 mod, stock carb, jetted. It has been running fine for three years, until this spring. It will run for three miles, then quit, and won't start. The three miles is the distance to  an intersection I have to stop at for traffic.

All these tests were a maximum of two per day, as I have other things to do. I thought it was fuel, so I changed to a non vacuum petcock, and a clear fuel line. And yes, I did block off the port on the carb. Three miles, and it quit again. I then thought it may be a coil problem, so I borrowed the coil from my son in law's bike. (Also a DRZ, just newer.) Three miles, quit. My wife is getting cranky about picking me up with the truck by now. Not the coil, so I went back to my coil, and traded CDI boxes. Three miles. OK, so I switched  the CDI's back,and bought a new plug. The old plug was a nice medium brown, but in with the new one anyhow. Same old same old. Now the bike cranks over just fine, it just doesn't start. That didn't faze me, I changed batteries just in case. Yes, three miles again. This time I just rode up and down our road, and of course, it stopped at the bottom of the hill. Not being terminally stupid, I walked to the house and got the truck myself!

So.. it seems to be somewhat heat related, as it will start after a period of time. All electrical items function fine, starter spins well, lights work, it just won't start. This is getting really frustrating!

I was at the campground watching the races yesterday, and someone said it was probably the regulator. The battery is fine so I'm not too sure about a regulator. Before I start randomly throwing money at this does anyone have a solution?

Marlin

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My guess is the stator. Very common fail point on these bikes, with all different symptoms.
Take your cover off and inspect it for burnt spots, black spot on the windings. You could do all the elec. tests but may pass them, since it has to get hot to quit.

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Check your oil for gasoline smell if you get even the faintest smell of gas change your oil
likely you’ve had some gas get into the oil

If not that then you need to do electrical diagnosis of the stator and pick up coil and check your valves

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I think it's fuel related. If you get good flow out your fuel line another place to check is the little screen over your needle seat in the carb. You have to remove the needle seat to see it though. If you're going to remove it and never have just buy a new one and filter because you'll screw up the old one taking it out 110% of the time. At least the FCR has this feature, assuming the BSR probably does too. If that screen is all clogged with goo and you're getting a very slow flow you can ride till the bowl is empty and then it quits until the bowl fills again.

I'm tempted to not think it's the stator. If the stator goes bad you typically get a no charge which would mean your battery would be dying, which it isn't. 

Spring is a good time to take the carb apart anyways, when you have a few hours take it out, tear it down, clean, and reassemble. Purchase any expanded or crumbling gaskets while you're in there.

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If you did not have to stop at 3 miles, would it continue to run?  Say for example you trucked it to a road where you could ride uninterrupted for 10 miles, would it die at 3? How long a cool down before it will re-start?

You are correct, it is not the regulator.  Possibly the stator.  Gas in the oil is a good guess.  Both fairly common and can cause the symptoms you describe. Check valve clearance is always a good idea.

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I forgot to mention that I also switched carbs with the other bike, so It's not a fuel flow issue. When it quits, I can open the drain screw and get a good volume of gas. As to running more than the three miles, I really can't say. If I go the other way, I'm out of cell range, and can't call for a pickup! It seems to run fine, right up until I pull the clutch to stop, and then it dies immediately. The clutch and sidestand switches have also been eliminated, so they are out of the picture. I will check and change the oil, and check the valves. As to the oil, are you thinking that the engine is getting tight due to poor lubrication? If so, why would it turn over easily with the starter, but not start?

And thanks very much for all the attention.

Marlin

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The motor could be getting tight due to the valve clearances closing up and when hot they could stick open ever so slightly causing loss of compression due to inadequate clearance when the motor is hot.The oil part is about fuel contamination.

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Have your wife follow you with the truck and go the other way to be able to run longer before letting off the gas. The first thing I'd do is take the sparkplug out and 1) check for spark and 2) see if it's wet or dry . That will tell you which system is messing up. Pop open the fuel tank cap to make sure the vent is working.

 

 

.

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3 hours ago, MarlinM said:

 As to the oil, are you thinking that the engine is getting tight due to poor lubrication? If so, why would it turn over easily with the starter, but not start?

No, as the oil heats up the gas in the oil evaporates and cause a gross rich condition and engine will not run,.

Valves , Hot no start is common if the valves are tight on clearance.. Engine starts cold, it heats up and runs, though somewhat less well if your noticing, then after stopping it, the lower compression for a slightly open valve keeps it from starting.  

Stator, its got nothing to do with charge coils,. those might still work and you have charging voltage, but the signal or pick up coil fails, outright (no start) or a heat related short or open .. BUT those tend to cause dying while running, not running till shut off then no hot restart.

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3 hours ago, MarlinM said:

I forgot to mention that I also switched carbs with the other bike, so It's not a fuel flow issue. When it quits, I can open the drain screw and get a good volume of gas. As to running more than the three miles, I really can't say. If I go the other way, I'm out of cell range, and can't call for a pickup! It seems to run fine, right up until I pull the clutch to stop, and then it dies immediately. The clutch and sidestand switches have also been eliminated, so they are out of the picture. I will check and change the oil, and check the valves. As to the oil, are you thinking that the engine is getting tight due to poor lubrication? If so, why would it turn over easily with the starter, but not start?

And thanks very much for all the attention.

Marlin

The fuel in the oil problem causes a very rich condition that the engine can't take when it warms up, basically floods the cylinder with fuel and the stock carb. has no clear flood provision. Won't start till it cools down and requires more fuel.  And yes , a plug check will tell you if that's the case, but smell that oil.

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It will be a couple of days before I get this done. I'll post any results. Thanks for the suggestions, and explanations. As a SWAG, with all the info, I'm leaning towards a stator problem. We shall see.

Marlin

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Marlin - The problem with gas in the oil is the gasoline vaporizes and the vapors return to the carb via the crankcase vent system.  This makes the mixture too rich to idle however at highway speed it will keep going.  Gas in the oil is not good for lubrication but it is the fumes that cause the motor to die not lack of lubrication.

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Well, thanks and congratulations to Mr. Marquez for the first correct answer. It was, indeed, fuel in the oil. I had no idea the vacuum petcock was leaking, I changed it because I don't like them. After I pulled the drain plug, I couldn't believe how much fuel had gotten in. I checked the stator and pickup coils, did the Locktite "fix", and buttoned everything back up. A new lithium battery, and it was time for a ride. Once again, my favorite bike is back, and running like a champ.

Many thanks to all who had an opinion, and or a suggestion. They were all appreciated. And Erik, if you ever come to Western North Carolina, let me know, I owe you a dinner.

Marlin 

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9 hours ago, MarlinM said:

And Erik, if you ever come to Western North Carolina, let me know, I owe you a dinner.

Marlin 

If the wife reads this, she'll be going wtf. Lol.

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