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Discussion Starter #1
I finally after many years of searching have found and bought an 84 Suzuki SJ410 Jimni.

The problem arrises in that it won't start... lots of spark, timing is good, firing order is right but as soon as you try to start it it loads up with fuel so bad it's running out of the carb inlet.

I took the carb apart and cleaned out every hole/jet and it's still doing it.

Can anyone shed some light on my carb issue?
 

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Discussion Starter #3 (Edited)
Ok, i took the return line off and stuck it into a pop bottle.

There is fuel coming out of it but the carb is still leaking fuel like crazy out of the air horn and the engine doesn't even try to start as the plugs get instantly fouled.

Is it possible the float valve and seat are shot causing too much fuel into the engine?

Where on earth do you get rebuild kits for these old Aisan carbs?
 

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Discussion Starter #5
ok got the carb back from the rebuilder, put it on and it still won't start.

i doubled checked the timing and firing order and all is 100%.

It sputters and coughs but won't start.... Any ideas?

PS. what are the best plugs to use in this engine?
It has some crappy champions in it now but they have a decent spark.

Gordon
 

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Are you certain the distributor isn't 180 degrees out? The timing mark on the crank comes around twice for every one rotation of the distributor. one time for the compression stroke, once again for the exhaust stroke. The dizzy should fire on the compression stroke. If the crank is at the TDC mark and the #1 cylinder is on the exhaust stroke instead of the compression stroke then you need to rotate the distributor 180 degrees.

I wish I knew more about the 410. I know enough to help you check general stuff, but not model specific stuff.

You might also want to do a compression test to make sure you're getting good compression and that your valve train is functioning propperly.
 

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Discussion Starter #7
Good News!

I got the old girl running with a new set of NGK plugs, cap and rotor... BUT... for some reason i now have more gas then oil in my crankcase.

I'm going to guess that the fuel pump has a bad diaphragm of O-ring in it causing it to pump gas into the head thus draining into the crankcase.

Gordon
 

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if it's a mechancal pump with the cam actuated arm then the diaphragm on it is probably ruptured and putting oil into the case. Change that sucker and your oil ASAP. Seems to be a lot of people with fuel in their oil pan lately.
 

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Discussion Starter #9
if it's a mechancal pump with the cam actuated arm then the diaphragm on it is probably ruptured and putting oil into the case. Change that sucker and your oil ASAP. Seems to be a lot of people with fuel in their oil pan lately.
Oil/gas has been drained from the engine... new filter and oil going in soon... then an electric fuel pump and an alternator.... maybe then i'll get to drive it...haha
 
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