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1999 Suzuki Carry bad performance...

Discussion in 'Suzuki Carry' started by Victor Getov, Jul 3, 2020.

  1. Victor Getov

    Victor Getov Member

    Hello Guys,
    A month ago I bought Suzuki Carry 1999 model DA52T with F6A engine, carburetor, manual gearbox and no distributor. It was parked in a yard for 3 years. I changed the oil and oil filter, put new spark plugs, drained, flashed and refill with coolant the water system, put new battery and managed to drive it home.
    Than the "little" problem with bad performance turned for me in a nightmare !!!
    I took out, cleaned, adjusted and reinstall the carburetor. Starts perfect (temp.10C), engine wants to dye, but after a minute small acceleration stabilizes and has the most beautiful idling. Refs like a fighter jet engine.
    But when start driving it - gives me max speed of 55 km/h with minimum acceleration. As soon as I press the pedal down - engine dyes in 30-40 seconds, again starts, idle and refs perfectly.
    While driving - no any sings of petrol shortage or misfire !
    Just no power !
    Nightmare !!!
    Please - help !!!
     
  2. Bigmac

    Bigmac New Member

    Plugged fuel filter?
     
  3. Limestone

    Limestone Well-Known Member

    Vic,
    Welcome! We've seen this multiple times, in units from mainly sitting, like yours has! Any time, a vehicle sets for a long period of time, dirty, bad or in sufficient fuel is a suspect! I had the same similar situation, By that I mean, If it were me I would drain the fuel tank completely, water is heavier than fuel, and settles to the bottom of the tank, even from condensation! There are several other post's on the forum describing and explaining these issues, if you use the search bar, you'll be able to find it! Any way, I would completely clean or replace the fuel lines, there probably original at 20 yrs. old! It's really not that expensive or hard to do. Not knowing the history of your vehicle, these are general area's to start! Even though you installed a new fuel filter, with bad or dirty fuel in the tank, the new filter can be, bad already! What about the fuel return line? It's very important that its not blocked or restricting venting also, probably, back to the tank! Go to G&R Imports, and read there tips on some maintenance issues, they do a great job explaining things there! These are just a few things to start with. Good Luck!
    Limestone
     
  4. Victor Getov

    Victor Getov Member

    Hi Bigmac, Thanks for your respond. Surprisingly - there was no installed filter between the tank and the carburetor. I put one in the very beginning. At this moment I am bussy taking the fuel tank out - to clean it and check the pump. I will post the findings here.
     
  5. Victor Getov

    Victor Getov Member

    Hi Limestone, Thanks for your respond. Just now I am busy with the tank - carburetor lines and will check the pump for constant pressure. I will post the findings.
     
  6. Jigs-n-fixtures

    Jigs-n-fixtures Well-Known Member

    After you get things cleaned up: The Trouble shooting guide that G&R Imports has on their webpage, is invaluable. And, if you get a chance pick up an old mother manual with the trouble shooting guide in the front. A guide designed for the pre-computer controlled engines is really handy when working on our older trucks, as most mechanics, and trouble shooting guides available now are completely dependent on being able to hook up to the data port and trouble shoot using the computer. https://www.grimports.com/maintenance-tips
     
  7. Victor Getov

    Victor Getov Member

    Hello again, I took out the tank. It was crystal clean inside. The pump filter was also clean. I put the pump itself in a small bucket with blue methylated spirit and run it on battery. It looks too weak. It can not blow even 10 centimeters vertical up. Can this pump be the reason for the poor performance?
     
  8. Victor Getov

    Victor Getov Member

    Hi Jigs-n-fixtures, Thanks for your respond.
    It seems my Zuki is model manufactured just before the computer operated models. It has carburetor, but no distributor. On the shaft of the flop there are three wires coming out and connected to a white socked. On top of this on internet I find only carbs with 5 vacuum ports. My carb has only 4 !
    Worst of all is that in radius of 1000 km around Maun (Botswana) there is no even similar truck like my. The bush-mechanics never saw one and refuse to attend it.
     
  9. Limestone

    Limestone Well-Known Member

    Vic,
    I was wondering what the fuel smelled like? Any hint of a varnish smell? I'm wondering how bad the jet's are varnished up! That dog gone stuff gets baked on those jets and will restrict flow, especially as you apply pressure to the throttle! I like the direction your headed in, eliminating things as you go! You'll get it, and then you'll know what you've got! I'm not surprised, that your the only one around with one, and there aren't any mechanics in sight to work on them. You see and hear this a lot! Good Luck!
    Limestone
     
  10. Jigs-n-fixtures

    Jigs-n-fixtures Well-Known Member

    And, if fuel sits in teh tank, and cooks off teh lighter volatiles, they charcoal canister can get clogged up, and not allow air into the tank fast enough.

    The little trucks with carbs want to see about 2.5 psi, which would be a water column of 130-mmHg or 70-in of water. So it sounds like your fuel pump is weak.
     
  11. Victor Getov

    Victor Getov Member

    After all blowings to clean the fuel system and runing the pump about 1 hour in spirit - everything was installed back and the test drive showed dramatic decrease in the performance.
    Now the maximum speed dropped from 55 to 40 km/h !
    Starting, idling and revs are like before - working perfect.
    Nightmare !!!
     
    Last edited: Aug 7, 2020
  12. Victor Getov

    Victor Getov Member

    Next thing I did was to completely bypass the fuel system. I connected external pump + filter from Jerrycan directly to the carb. Zero improvement. Perfect starting, idling and revs in the yard and chocking and dyeing on the road.
    Nightmare !!!
     
    Last edited: Aug 7, 2020
  13. Limestone

    Limestone Well-Known Member

    Sounds like a carb. rebuild is in your future!
     
  14. Victor Getov

    Victor Getov Member

    Tomorrow is going to be AGAIN carburetor day. Here now is 01:15 ...
    It is burning too rich - the spark plugs - brand new - are already with black, sandy deposit and it seems the accelerator pump is giving too much fuel - can not thing for other reason to drive with minimum acceleration and dyeing if the pedal is pressed to the bottom.
     
  15. Limestone

    Limestone Well-Known Member

    Everyone who has had these similar situations, had to rebuild their carb.!, but you had to eliminate the rest to get to this point!
     
  16. Victor Getov

    Victor Getov Member

    In this situation with Corona-19 for me rebuilding the carburetor is like Mission Impossible -55 !!! Even if I order carb kit from AliExpress it is with "Unknown delivery time" - from 3 months to never.
    Today I just opened the exhaust pipe - to make sure there is no clogging in it. It is in perfect condition.
     
  17. Limestone

    Limestone Well-Known Member

    I know, it's pretty frustrating, and yet there's nothing we can do! Probably not a bad idea, to eliminate any and all possible unforeseen problems!
     
    Last edited: Jul 27, 2020
  18. Jigs-n-fixtures

    Jigs-n-fixtures Well-Known Member

    Have you done all the things the G&R link I gave you above? Carbs. Get blamed for a lot of problems you can fix with electrical and tuning issues. A bad ignition coil will also cause the problems you are having.
     
    Limestone likes this.
  19. Victor Getov

    Victor Getov Member

    I have done everything from G&R. Still no any improvement.
     
  20. Victor Getov

    Victor Getov Member

    At this moment I have half tank of fresh fuel and, by advice from a friend I added 500 ml of brake fluid.
    ZUKI GOES LIKE CRAZY !!!
    It is not 100% yet - I thing my vacuum hoses are mixed around. And I am still battling to find diagram for 4 vacuum ports carb.
    I will post update after I put new fuel without brake fluid.
     
  21. Victor Getov

    Victor Getov Member

    Hi Guys, I (nearly) finished the petrol with brake fluid inside and filled fresh petrol with no additives. The performance is still amazing !!! It seems there was some blockage witch was "blown" by the brake fluid. Despite the mixed vacuum hoses I am happy like pig in the mud !!! I will give another update after I finish at least other tank of petrol. Thanks a lot to all of you for your advises. They really helped me !
     
    Limestone likes this.
  22. KCCats

    KCCats Active Member

    Never used brake fluid, have used ATF and I love Sea Foam!
    Hey I just went threw what you are, I bought a carb from a DR650 and so far WAY better!
    Check it out in thread Carb Swap out
     
    Limestone likes this.
  23. Victor Getov

    Victor Getov Member

    UPDATE: Mechanically my happiness was very short. After the tank with brake fluid was finished my Zuki went back to the point I bought it. But not me !!! During this time I spent a lot of time reading from different sources. The problem is between petrol tank and intake manifold. This is for sure. Carburetor out. But now I looked at it with another eyes.
    It seems Ali Baba and 40 thousand thieves were playing with it !!!
    1)The Throttle Position Sensor - working, but out of adjustment. It was starting it's reading not from 0.5 Volt, but from 1.5 Volt ! Wrong adjustment. Fixed. Now starts at 0.5 Volt and reads up to 4.9 Volt. Perfect.
    2) Plunger out. In the "Desperately need tuning help" discussion Spaner posted picture of plunger, needle and instructions. It was SPRING - WASHER - SPACER - CLIP. I made it SPRING - WASHER - CLIP - SPACER. This dropped the needle +/- 6 mm down. Maybe this was the reason to run TOO rich. Plunger back.
    3) I looked at the throttle. It is not closing 100% - maybe 0.2 -0.3 mm gap. Still busy on it. I will share the outcome after test drive.
     
    Last edited: Aug 4, 2020
    Limestone likes this.
  24. Victor Getov

    Victor Getov Member

    Hi KCCats, I was told, that brake fluid in the petrol makes the engine to burn all carbon deposits on spark plugs, pistons, valves, EGR ...
     
  25. KCCats

    KCCats Active Member

    ATF Does too.

    So when you are done messing with the carb I think I have a FIX!
    I have spent the last 3 years with that Junk OEM carb!
    And don't get me started on China Crap!
     
    Limestone likes this.
  26. Victor Getov

    Victor Getov Member

    I have read the "Carb Swap out". Very carefully. Four things make something like this Mission Impossible for me.
    1) Covid-19 crap - if I order Grizzly, Rhino or something else from Amazon or AliExpress the delivery time is from 3 months to never - I am in Botswana - Africa.
    2) I have Throttle Position Sensor on the carb, and there is no way to modify the new carb - the closest lathe machine is 945 km from me.
    3) My Zuki is different than yours - no distributor, 4 ports Thermal Vacuum Switch, 4 ports carb, radiator right in front, fuel pump inside the tank, only access to the engine room - from under the seats. So, I can not expect help from the other members based on personal experience. But I am VERY VERY thankful to this forum - the information here is GREAT !!! For a month reading I learned so much !!!
    I am a boilermaker, and from all boilermakers in Botswana, now I am the best car mechanic!
    I wish I had more knowledge to donate to everybody !
    4) The shops here (Maun "town", Okavango Delta) - two in total - are empty like Church on Monday. Today I asked for Fuel Pressure Regulator and the sales people looked at me like I was asking for a Stone made out of Wood.
    As you can see - Snake ahead and Cock behind is my choice !!!
    THE GREAT NEWS IS - I FOUND THE PROBLEM !!!
    This morning I cut the positive wire and installed a On/Off switch between the relay and the petrol pump - for security reasons. Went to see a friend.
    On the way, I switch Off the fuel to see how long can drive only on carb ... and in few seconds...
    ZUKI GOT POWER !!!
    On-Off, On-Off, On-Off ....... goes like a real truck !!!
    Fun enough - when I tested the pump (visually) in the beginning - I thought it gives not enough fuel !!!
    I run to the shops for Fuel Pressure Regulator ... Bad luck ... Pump ONLY for Fuel Injection - 25 to 40 PSI ... Bad luck ...
    At this moment I am busy putting a T-piece before the carb and run another hose back to the tank - to reduce the pressure from the pump.
    I shall post update tomorrow - here now is 21:42 and I am still far from finish .....
     
    Last edited: Aug 4, 2020
    Limestone likes this.
  27. Kim Smith

    Kim Smith New Member

    I'm almost in the same boat. I bought a new carb and put it on and now it will only run if you hold the pedal to the floor and it want run of 2000 rmps and as soon as you let off the gas it dies.And i have the same truck as you have. I'm thinking it may have a bad fuel pump.
     
    Victor Getov likes this.
  28. Victor Getov

    Victor Getov Member

    Hi Kim, The good news is - you are on the best Suzuki Forum on the web. Please, give more details for your truck - make, model, history ect. .... Seems you also don't want to feed "car mechanics" - great !!! Describe in details your problem and I am sure with so much people willing to help you will get it right. Zuki's are tricky, but are vehicles with soul. I fell in love with them some years ago after driving one for a month. Despite the problems with mine - I already put +/- 2000 km on the clock.
     
  29. Kim Smith

    Kim Smith New Member

    First off a friend of mine had this Suzuki Carry 1994 F6a DD51T sitting in the yard and i bought it and I love it!!! So my friend said he could not get it to start with the key that you had to pull it off. Well i took it home started working on it and tried to pull it off would not do nothing.Tried spraying carb fluid in the carb and it wouldn't do anything.Its like the more fuel you gave it the harder it was to get it to hit off.Well i got a idea and hooked another battery to it and it spun a lot faster and the faster it spun the more it wanted to crank.Well i kept doing it and it finally started up but would do nothing but barley run.So i kept running it and running it and it spit back and started running and revving so i was happy as could be and drove it all over the yard.But you still kinda had to keep revving on it to get full power.So i go out the third day and i cant get it to start and it spitting back through the carb very bad. So i said ok its time for a new carb. I buy a new carb but its the 3+1 instead of the 2+3 anyway i do all my research and hook all the water lines back up the factory way. And the vacuum lines where tough but I'm pretty sure I got them right.So i go to fire it up and pretty much the same crap! After several times I got it to start up and ideal but that's it if you give it gas it goes dead. I check the fuel pump and it seems ok but not a whole lot of pressure.
     
    Victor Getov likes this.
  30. Kim Smith

    Kim Smith New Member

    Update so I started it up this evening and still the same thing.But i stuck my finger in the carb and held the flap wide open and it started running better and it started revving some what good. Did it again and it started revving and i was getting happy and I let off the gas and it died again. I just don't understand.
     
    Victor Getov likes this.

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