Motorcycle Repair: 1982 Suzuki DR 100, suzuki dr100, plug caps

Question
Well her is the problem i have 1982 Suzuki DR100 that need to have the timing set and not sure how.Can you please help Single Mom in Ca.

Answer
Fancy, I dread the non-Honda questions like this. According to Bikebandit.com there is no DR100 in 1982. I found a DS100x in 1981 and a DR125 in 1982. The DR100D comes in 1983. Maybe it was sold in 1982 as an 1983 model. Apparently the DR100s were made from 1983 to 1990, so hopefully parts are plentiful. DR125 parts may be similar, as well.

All that aside, the ignition systems on these bikes are non-adjustable CDI. A $225 CDI control box does all the decision making. If you are getting wrong timing or no spark, you have to start with the pickup coil under the flywheel to see if it is generating the pulse to the CDI module, which relays that on to the ignition coil. Have the coil checked, as well as the spark plug cap. Plug caps have a resistor inside (usually), so sometimes they get out of range or go open and the spark is weak or non-existent. Change out the control module, only as a last resort, after you have checked all the inexpensive stuff.

If you are having performance issues, have the spark output and timing verified, using an automotive timing light with the engine running. The ignition is more or less pass/fail, so if it is working properly, then your problem probably stems from some kind of carburetion issues. With today's fuels, you can't just park any motorcycle for a couple of weeks and have it fire back up again. The fuel separates and clogs the idle jet. Then they don't start well, if at all. If you do get it started, then it won't idle. Clean the air filter, while you are at it.

Who told you that the "timing was off," in the first place?
Sounds like someone was guessing, rather than diagnosing the problem correctly.

Alway start from the beginning:

Compression.. have it checked and/or adjust the valves so compression can be maximized. Honda valve clearances are about .002" on an engine like this, but your Suzi may vary from that considerably.

Clean the entire fuel system from tank to float bowl. Put in fresh fuel. Also check the oil level, so you aren't subjecting the engine to a possible seizure episode.

Check all electrical connectors and ground contacts.

Okay, "MrHonda" is done with this Suzi question.

Good luck with the repairs, Fancy... aka Single Mom Suzuki Repair person.

Bill Silver