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I recently stole purchased for a very reasonable price a 2004 DL1000 knowing it didn't run right.
Three months later I've exhausted all my knowledge and haven't gotten it running properly.
I decided to start a new thread rather than muddy-up RandyO's V-Strom build thread.
Symptoms:
- Starts.
- Idles.
- For the first 90 seconds of running time, it'll accept low throttle openings.
- From then on, it won't accept throttle at all under 5,000 rpm. It will sputter and die.
- The one time I was brave enough to take it out on a highway it was beyond frightening. It would only stay running over 5,000 rpm. (Try pulling into your driveway like that!)
What I've done so far:
Scoured the Stromtrooper forum and VStrom.info for ideas
Downloaded the shop manual and wiring diagram
Put it in dealer mode and checked for codes - none
Checked the air filter - it's fairly new and in excellent condition.
Adjusted the idle speed
Installed a new throttle position sensor (and adjusted it properly)
Installed a new battery
Uninstalled a set of relays put in by a prior owner for electrical accessories
Ultrasonic cleaning of the injectors
Confirmed that the tank is properly vented
Confirmed that the throttle bodies are tight to the air filter housing and to the intake boots
Sprayed carb cleaner on all the linkages - everything moves freely
Tested the fuel pump (slightly below specs)
Disassembled fuel pump & ultrasonically cleaned (a bit of gunk, not much; output improved after cleaning to a bit better than specs)
Trim plug wires (following post #2 below) (could easily reach rear; did not do front)
Sought out corroded ECU contacts (post #12)
Things still to do:
Check throttle-body sync
Upper throttle-position sensor (following post #5)
Seek out corroded electrical contacts elsewhere.
I'm obviously missing something, but I'm now stumped as to what it might be. I could continue throwing parts at it (like a new ECU) but that's going to get very pricey very quickly.
So, NESR brainiacs: Where do I go from here?
Edit: I'll put a similar post on Stromtrooper.com in a day or two.