Carb settings etc.

[Smallkat]

The engine doesn't really go to 12,000 rpm, it's limited to 10,500.

Fairly sure over 150 psi is good for compression. Even values is more important in my opinion for a road engine.

Now, don't ever think the magical carb fairies aren't fooling you. They let you think all is okay and then it isn't. I don't know how they do it!

As you seem to know what you are doing on the electronic front, I think that is your best course of action. I think Bill put a new battery in it, so maybe there is a problem somewhere there.

[johnD]

Hi Smallkat. You are probably chortling to yourself, seems I'm not the only one driven to distraction.
Just having a brew after putting it all back together, I'll try a start when I have sacrificed a virgin, not many of those in Salford!
So, if the carbs are so fussy, has anyone tried a replacement? Given that these seem the same as those on the 600 Bandits, they may well be a tad too large choke size for this motor?
But, a good spark will ignite the most woeful of mixtures.
I'm busy researching a simple CDI (NOT TCI) ignitor box. These give a far hotter spark, that's why they are a universal fit to modern bikes and cars.
Incidentally, I HATE lost spark coils. They halve the 'power' of the spark unless the 'igniter' unit is delivering a high current to the coils. And it only takes one of the plugs to foul short curcuit to cut the sparks off completely to two cylinders.
Whether these Chinese boxes are of borderline efficiency I'm not sure, but mine is new, sqeaky clean and works as intended. I presume a PO, (Bill?) replaced the original.
But, here we are. I have dealt with some recalcitrant machines in my time, now I begin to see why the lore of the 400 Suzuki is well deserved.

[Smallkat]

I would laugh, but I have been there twice (once with the 250) and I feel super-lucky that mine seems to be behaving itself now. I have a lot of sympathy for you, as I know how frustrating it can be. At one point, I just put Smallkat in my father-in-law's garage so I wouldn't have to look at it!

It started first time today but about 5 miles into my ride it started stumbling at low revs. This was intermittent, so I just revved it more!

I think alternative carbs would be a good idea, but the time, hassle and cost of it may be prohibitive. There must be 'performance' carbs available in Japan, but again, cost will be high.

[johnD]

My woes mount. Trying to start but the starter motor seemed a bit sluggish. Charged the battery again and it spun over, but, moitoring the 12v supply, it was dropping way below 12v, nearer 9. No way the igniter will work at that voltage. Starter motor now removed, to be dissected after a nice tea of Barnsley chops, mixed vegie and some baby potatoes drenched in butter. (While iI can still afford it....).

[Smallkat]

Bill definitely told me he fitted a new starter motor.

Mmm... I not supposed to eat butter (and a load of other stuff) after my recent gall bladder problems, but it sounds great. Maybe better to get your enjoyment from saturated fat rather than 400 Kats?

[johnD]

Starter motor dead, all that churning I presume. Replacent ordered,
Funny, the only easily available spares for these are.... Carb rebuild kits..... and....... starter motors!

[johnD]

Hi all.
Been a bit quiet as I've been chasing my backside in ever decreasing circles. At least, all my other jobs are done so I can properly commit all my remaining patience to this (expletive deleted) motorcycle.
I'm closing this thread as I am opening another regarding the TCI igniter unit.
Thanks for your forebearance with me so far....

[Smallkat]

It's easier to start a project thread that covers the whole bike (or follow on from william.sn032's thread). Keeps all the problems for one bike in the same place!