I just bought a 1996 Suzuki DS80 for $80 and everything is in great shape except the fact that it won't crank. It still has compression in the kick so I'm pretty sure it's ok so far, I just need to fix the problem. I ordered a new air filter so once that comes in I'll install it. Also the guy I bought it from put a new spark plug in but I'm not sure if it's getting spark, so I'll check that out this afternoon. Also I just put 110 octane gas in it and redline oil and when I did the gas line was leaking
Suzuki build thread- project bike
- Thread starter Lovespeed
- Start date
I'm going to either patch up the spot where it's leaking from in the gas lines and if that doesn't work I'll just get them replaced. Also yesterday I hooked up the throttle line to the handlebar since it wasn't hooked up and when I twisted it, it wouldn't move. The cable wouldn't move at all so what would I need to do to fix this? Is it seized up? Thanks
You have some serious mechanical issues here. We may need to call in @Naturaledge. He has the ability of a Canadian master mechanic but rarely uses his skill. 110 octane 
that alone may have scared the motor to a frozen position.
that alone may have scared the motor to a frozen position.You have some serious mechanical issues here. We may need to call in @Naturaledge. He has the ability of a Canadian master mechanic but rarely uses his skill. 110 octane
Should I use a different octane? I'm not sure what gas but the store told me to use 110 octane for now to get it started.
if you have compression in the "kick" I'm assuming when you say it won't crank you are meaning it won't start?
Yeah, that's some high octane....you should be fine just running premium pump gas 92/93 octane....
did the throttle turn before you hooked up the cable?
unscrew and pull the slide out of the carb (where the cable goes into the carb) and then try turning the throttle with the slide out of the carb(be careful not to damage the needle when the slide is out).....the slide should freely slip out of the carb....If the throttle turned before you hooked up the cable and don't turn with the slide assembly out of the carb then yes the cable is seized up...
fuel line is very very cheap($1 a foot)...don't try and patch it, replace it!
Replacing the fuel line should be a simple job(take you just a few minutes).....
getting the slide out of the carb all depends on how much room you have to work (if no room to get the slide out you'll most likely have to remove the carb to get it out, you need a bit of room to lift it up out of the carb, you don't want to bend/break that needle).....did the throttle turn before you hooked up the cable? if you never checked I'd start there (take the cable back off and see if the throttle turns with no cable hooked up first)....he had the cable unhooked for a reason.....
good question...I would assume there are different sizes but it won't be a special order item....If you can't take your old one with you (try to though) just have them look up your bike....you will be able to get fuel line at any local bike shop....If you do take your old fuel line with you, you could even go to a auto parts store....I prefer fuel line you can see through
but it's not a must.....If that is the case then the needle and seat assembly in the carb is stuck open or not completely sealing or your float in the carb is sticking not letting the needle and seat seal....(that has to be fixed if you want it to run/run right).
If it was my bike the first thing I would do is a compression test and check for spark (if it has no compression doing anything else is a waste of time and money until you verify/get a good top end/compression) just because you feel compression on the "kick" don't necessarily mean it has good enough compression to run....To make sure you have spark (pull the plug leave the plug wire on it and kick it over, you will see the spark at the spark plug).
once you confirm good compression and spark see if that throttle cable is froze up or the throttle itself is (a throttle cable is cheap).....then I'd just buy a carb rebuild kit (I just bought a rebuild kit for my sons 2001 RM 125 yesterday for $28) a carb kit comes with all new jets, needle jet, needle and seat, all o-rings and gaskets needed to rebuild the carb) you can buy just a new needle and seat but for the price of a complete rebuild kit, a complete rebuild kit would be the way to go.....with the needle and seat stuck open/not seating(or float sticking) I'm sure that carb is dirty and in need of a good cleaning anyways.....
also...If you plan to put a few bucks into the bike and keep it....the best money you can spend is buying a service manual for the bike...you can probably(if you're lucky) find a downloadable manual online for cheaper than buying the book itself.....
and remember when buying parts....especially parts you have to order...ebay is your friend!!! parts are usually cheaper and delivery is about the same as your local parts store order time....
keep us updated...and best of luck to you!!!
a cleaning is not going to fix a bad needle and seat.....so yes,I would buy a rebuild kit (i wouldn't buy anything until you verify it has good compression and spark)....and yes it has to be a carb rebuild kit for a 1996 Suzuki DS80...
ebay isn't showing one, so just give your local suzuki dealer a call and get a price ( will most likely have to be ordered)...