Need help urgent !!

[Greggio]

Hello peeps I really really need as much info/help as poss.
What I've done is stripped the tank off replaced air filter and cleaned all throttle body linkages and sprayed with acf50 I have rebuilt the bike and it took some starting and it misfired running rough etc I give a couple of fistfulls and it cleared I turned it off and left it till I did suspension seals and various other stuff ready for st6 and finished it off last night fired it p and went to scrub new tyres in which is when I realised it was running as rough as a badgers misfiring and cutting out at junctions so today I fully stripped the bike and checked all connections cleaned all coilpack terminals and mounting points checked the injector harness all OK put new plugs in. built it back up ensuring everything is plugged in properly and all vacuum pipes etc are connected and started it up with no difference still the same running rough although it is firing on both cylinders I unplugged the coil packs one at a time and it did change how the bike ran significantly so I rang my local dealer and they can't look at it till wed which is only giving them 2 days till strom trekker 6 which is cutting it too fine for my liking so if anybody can shed some light that would be great cheers

[Locky]

Thanks Greggio    . Yes what a nightmare just before ST6 !! I've googled "Suzuki DL1000 misfire" and loads of stuff comes up , have a google . Are the inlet rubbers seated correctly , it can be hard to see them if they are like the 650 ? You could of disturbed them ..It does sound like a simple fault if it was OK before you stripped it ..Have you had the bottom part of the airbox off ?

[Locky]

Come on Greywolf ...

[mr_diver]

viewtopic.php?f=58&t=13837&p=149572&hilit=running+on+one+cylinder#p149572

might help?

[greywolf]

There were too many things done at once for a definitive answer. If there is no FI reported, checking for an air leak is a good idea. Besides a visual inspection of the throttle body boots, Spray some WD40 around the throttle bodies and check the exhaust for smoke. Did the new air filter come with an edge gasket? It's been years since they didn't but it's something to think about. A TPS and TBS adjustment may be needed.

[Sven]

My mate (Bumhead) had a similar problem on his Vee. After checking loads of things, it turned out to be a TPS problem. He replaced his & set it up so I'd give that a check.

[Locky]

Yes you could have disturbed the TPS position ..

[mr_diver]

when I disturbed  mine it took me weeks to get it running right again...

she idled like a pig, spluttered, smoked and died... or just wouldn't start.

[Jacko]

How would you go about resetting the TPS..?

[Greggio]

I've completely removed throttle bodies now so I can clean and inspect the rubber mountings but as ar as I'm aware I didn't remove or touch the tps  all I did was change the air filter and spray the rear throttle body linkage with carb cleaner and spray with acf50 I couldn't get in to the front one but I have now unplugged it all only the connectors the tps is still in place ill see more tomorrow

[greywolf]

Some of that ACF-50 could have become sucked in and fouled the new plugs.

[Greggio]

Some of that ACF-50 could have become sucked in and fouled the new plugs.

I cleaned off the acf today then replaced plugs still same the only changes I did we're air filter none genuine but I've put the old genuine back in still same and put my baffles in the exhausts so I'm going to clean all intakes thoroughly and put throttle bodies back on and put a new genuine air filter which will be here tomorrow and Ill try it if its same ill whip the baffles out see if it changes ill also check wiring further down loom near rear head as diver said

[Greggio]

Update is cleaned throttle bodies thoroughly and set stv sensor with ohm resistance meter to manual re-installed throttle bodies and checked dealer mode and I got _C00 so I've adjusted tps to read -C00 as per manual built back up with new air filter checked dealer mode perfect with no codes started it up and it does seem to be better than it was I removed exhaust baffles and seemed better again so now its not too bad I'm going to road test later and still get it to local dealer see what he thinks

[jimbo8098]

I'm with greywolf here , check the airbox is all tightened on properly. If it isn't , the bike won't have the same compression as before and will cause problems like you are experiencing. Check all the little rubber seal is where it should be too,

I had the same problem with the XT at one point... Although there was a strong smell of cow dung when I did...

[Greggio]

Still got problems blokes I've sprayed around intakes on idle with gt85 now if I had a problem of it drawing in air it would alter how the bike runs but it doesn't and there is no faults on fi system so I have come to the conclusion that it is a fuelling issue but not electric so I'm going to clean the lines and change the fuel if its no better after that then I'm just going to ride it on st6 regardless if she blows she blows maybe someone might be able to help at st6

[Locky]

Seems very strange and must be something you disturbed . What about the fuel filter in the tank ? Is there a way of testing fuel flow from the pump ?

[Jacko]

You haven't pinched a fuel feed while replacing the tank have you?

[Greggio]

definitely not pinched any pipes I must have had tank on and off 10 times now as for the fuel filter I didn't even know they had one I think ill check or replace it when I drain the tank but like I said I've waited too long for next week and got way too excited to be beaten by my bike. now I'm off work and have a full week to get it sorted even if I've to strip heads and check valves and timing   if anybody has some spare injectors they could bring just incase or if any really generous vee owners let me try their ecu just to eliminate it from the list it would be great  

[Strommer]

You do have a gasket on the non oem air filter don't you?

[Greggio]

Yes I've bought a gen air filter now just in-case