Suzuki SV 650 2004 runs but only up to 5000rpm for a while and then quits...does this relate to the fuel tank recall? or some weakness in the fuel pump. I do not have the manual, could I get the trouble shooting section of the manual relative to this problem?

Hi and welcome to FixYa!

Yes it may but as a first course of action I strongly suggest that you replace the fuel filter. It can be clogged causing fuel supply irregularities. If it still doesn't help then replace the fuel pump and you'll be good.

Hope this helps and thank you for using FixYa! Have a good one!

Suzuki SV650 Recall 2003-2006 models
Make / Models : Model/Build Years:
SUZUKI / SV1000 2003

SUZUKI / SV1000S 2003-2006

SUZUKI / SV650 2003-2006

SUZUKI / SV650S 2003-2006

Manufacturer : AMERICAN SUZUKI MOTOR CORP.

NHTSA CAMPAIGN ID Number : 06V013000 Mfg's Report Date : JAN 11, 2006
Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY
Potential Number Of Units Affected : 4841
Summary:
ON CERTAIN CALIFORNIA-SPECIFICATION MODEL MOTORCYCLES, REPEATED STRESS FROM VIBRATION CAN CAUSE A CRACK TO FORM IN THE AREA WHERE THE LIQUID/VAPOR SEPARATOR BRACKET IS WELDED INSIDE THE FUEL TANK. THIS CAN ALLOW FUEL LEAKAGE TO OCCUR.
Consequence:
FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy:
DEALERS WILL REPLACE THE FUEL TANK FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN IN FEBRUARY 2006. CUSTOMERS MAY CONTACT AMERICAN SUZUKI AT 714-572-1490.
Notes:
SUZUKI RECALL NO. 2086. CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.)

and his is a torrent that you can download the service manual for your bike. if you don't know how torrents work please let me know. www.utorrent.com is a good site to get a torrent program if you don't already use one.

robert

Clean the petrol tap ,behind the tap is a gauze filter and this i think is choked up a bit with rust ,tank comes off easy ,most models have a bolt under seat ,remove this and then slide the tank back a bit and out it comes .

If it was carb related then shouldnt it still have some side effects when it is not under load (stated it redlined in neutral) or no?

I am not sure, but I would have thought it would have problems even without load. Fuel pump full of ****? Vaccume line cracked?

I quote additional details...
Deductions:
-- Prolly not overheating coils, as the bike runs fine after the ride.
-- Bike likes to rev with less restriction (leaner).
-- Problem slowly returns, so has to be something that eliminated a condition with removing the airbox, then returned that condition under load when it returned. Not plug-related.

Things that could match up the symptoms:
-- A very high fuel level, with a rust problem in the pilots.

If the pilot is lean to begin with, excessive richness can only manifest so much in the pilot circuit, as it can only flow so much, and the screw won't be totally 100% open (perhaps blocked by rust powder as well, like mine, to cause even more leanness, allowing it to feel fine when the choke was causing extreme richness). It can however, affect the needle jet/main, as that circuit flows a lot more fuel. Opening the choke will quickly deplete that fuel back closer to what the level *should* be, causing it to run well. Once a few minutes riding pass, and the leaking float valve allows fuel level to creep back up to where it was, the symptoms return. This won't happen when the airbox is back on, as it tips richness to the point where it only revs unloaded. Rust can also exist in the main jet holder, only allowing the topmost emulsion tubes for the needle jet to work. Kind of a stretch, though.

That's the only one that seems to match roughly. I am intrigued by the 'running sans airbox seemed to cure the problem with the choke'. Try the same test with just the air filter out -- can you reproduce the good running you had with the whole airbox off?

Otherwise, I'd check the float valve for proper function, plus float height (and fuel level if you can), then immediately remove the main jet and holder, and look at the needle jet holes. Since this is a problem isolated mainly to the top of the rev range, I'm intrigued at what could be the cause... gotta be something simple. If you have compressed air, give it a squirt down the slide hole with the slide removed, down the needle jet opening in the venturi.

Hope helps.

Very possibly - the engine doesn't rev as high as it should because the fuel reaches it in a very low quantity and even that slows below the minimum necessary to function. The recall was caused by a vacuum valve on the fuel tank cap that it's stuck closed - when the fuel is pumped out air must come in to take it's place; if air isn't coming thru the valve vacuum is created in the tank which counterbalances the suction force of the pump = lower fuel debit; when the vacuum is greater that the suction force of the pump the fuel flow stops, cutting the engine.
But it could also be a failing fuel pump or a clogged filter - you will need to check them also.