Loss of power above 3500 RPM

[Spiggy]

My 1994 Voyager while on the highway at 70 MPH suddenly bogged down, I had to add some choke to keep it running to get home. We had just filled it up with gas 15 miles or so before so I thought water or crud in the fuel. It was late in the fall so I was going to work on it for a winter project, unfortunately that sat for several years because I just rode my other bikes, and when did go to start it, (started within 40 seconds with the old gas in it). would hardly run with the choke full on and could not get above an idle. The tank has been cleaned the fuel filter changed and the fuel pump replaced (checked with a low pressure gauge and I have 2.5 to 3 psi). The carbs have been ultrasonically cleaned and float levels set, synchronized and new spark plugs and tune up. I have the 12*** ignition module. Now I am at the point where it will run up to 3.5 k rpm and it stalls above that (same as original symptom) like starving for fuel unless I have the choke on (which with some choke I can get 5 k to 6 k rpm but runs poorly not loaded) I can not put it under load as I have it torn down to the point of the gas tank just sitting on the frame. I have a video of it from a cold start and trying to get it up above 3.5 k rpm but not sure how to get video linked. I am at a loss using the repair manuals troubleshooting guide.

[triton28]

It seems to me that there must be something still amiss with your carburetors.
Just a suggestion but check the rubber diaphragms for any holes or tears and I hate to say it but if it were me I would recheck the pilot, needle and main jets along with the receptacles they fit into, for anything which may still be there causing a blockage.
I would also suggest contacting Mr. Carl Leo as he is the man for solving unusual items such as yours.
voyagerparts@bellsouth.net
Good luck,
Dave

[Mr Jensee]

Spiggy contact Carl Leo with your symptoms and what you have already done. I am sure he has some answers with little guessing as to the problem. The rest of us can only guess what might be the problem. Understand that for an engine to run it must have air (is it starving?) it must have fuel flowing for it's needs and it must have spark. Any one of these three could be the culprit. Some questions need to be answered. Does this happen right away or only after the engine is warm? Is the fuel pump pumping adequately and consistently? Have you cleaned the air filter and checked for obstructions in the air box? When did you last change out the plugs and are they the right ones? Carl can help you much better than I can. Send him and email to voyagerparts@bellsouth.net.

[Spiggy]

Thanks I will contact Carl

[Spiggy]

To Carl Leo

Carl

I checked the items in the fuel delivery system that you had suggested, and found they all seemed to be functioning properly. I decided as I had said to clean the carburetors yet once again and in doing so I damaged one of the main high speed needles, finally got it in this last couple of days, my son and I installed the carburetors and the fuel tank new fuel lines and the second new fuel pump, (first one developed no pressure) when I talked to you I was running the original pump and it had 3 psi. I put the new pump on since I had it here and the age of the original. My son and I went through the book step by step double checking everything and found no problems. When done I told my son that we would synchronize the carburetors since he had never done so. low and behold I twisted the throttle and it shot to over 7000 rpm. As soon as I could get the bike back together enough to test ride it I did so and it runs great. I have no idea what the problem was but it is running now and hope to go for a small ride to test it out further with the bike fully assembled. I am extremely perplexed at not knowing the cause, and I thank very much for the time you gave to help me out on this. I am looking forward to taking this on our twentieth anniversary ride, we are going to try and duplicate our honeymoon ride we took on this bike around lake Superior, getting all the same photos that we had taken then.
Sincerely Floyd and Adrienne Smith

[Mr Jensee]

Spiggy it has been my experience that when you have four carburetors and they are not synchronized it causes a delay in response to one or more cylinders. This causes the cylinders to work against each other and that can cause that rev limit you experienced. I learned a lot about this stuff when I owned the 79 GS Suzuki 1000 I had. It was the first four cylinder bike I ever had, brought it back from the dead and wound up replacing tons of parts on it. Ignition and carburetors can drive you nuts trying to get them right. I am just glad you got your Voyager running great.