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installing jd kit on DRZ400E

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James,

just got the kit and want to install but not certain which jet to use. Stock pipe, coast enricher removed, pilot jet 48, PAS(still haven't tried your recommendation), Adjustable fuel screw at 2.5. Sea level to 600 ft MSL.

Recall I had problems getting bike to idle down with PAS set at 1 turn, it will idle down at 1.5. I have sprayed outside of intake area while running and can not detect any air leaks. I have double checked for leaks where I removed coaste enricher. Where else is there to look???

Should I use the 155 main or something else???

Thanks, Mike c

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This is an estimate based on our discussion and your specific situation-

#48PJ

1 turn out on the pilot air screw

1 1/2 turns out on the fuel screw

Blue marked needle in middle clip position

#160 main jet

Inspect the fuel screw, washer, and O-ring. Spray carb cleaner in this passage when the fuel screw is removed.

Let me know your progress.

Thanks,

James

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This is an estimate based on our discussion and your specific situation-

#48PJ

1 turn out on the pilot air screw

1 1/2 turns out on the fuel screw

Blue marked needle in middle clip position

#160 main jet

Inspect the fuel screw, washer, and O-ring. Spray carb cleaner in this passage when the fuel screw is removed.

Let me know your progress.

Thanks,

James

James, I completed your recommended steps. The bike starts and runs but is still way too slow to idle down. It takes at least 5-8 secs for it to settle back to idle and it does it abruptly. when I turn the PAS out it helps a bit but still does not settle the way it should. Obviously when I turn it in the engine will idle up.

I removed the carb and all jets. Cleaned and blew it out. I have not reassembled it as I would like you input before going forward.

Is it possible that the 48 slow jet is too much? Should I go back to the 45 or will it not make that much difference.

Frustrated???!!!

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Is the carb slide plate installed with the square end down?

http://www.pbase.com/jdjetting1/image/25566126

Does the fuel screw have it's spring, washer, and O-ring installed and in good condition?

What is the float level set at?

It seems like there is an air leak causing the fast idle or a fuel/float level problem.

Try the blue marked needle with clip position #5 as the next step if everything checks OK. A richer fuel mixture should drop the idle speed more quickly.

---Air screw 1 turn, fuel screw on bottom of carb at 1 1/2 turns, #48 PJ, Blue #5, #160MJ

Your frustration is understandable, it's not a typical condition with these settings. There are hundreds of 400/520KTM's ('00-'02), YZ/WR400's, and DRZ400's with this carb using a #48PJ/100PAJ and no problems like your bike.

James

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James, I checked the spring, washer and o-ring. They all appear fine. I suppose the O-ring could look ok and still cause a problem.

The float is set between 9-10mm. manual recommend 9 +/- 1mm.

I moved the clip down to #5

engine start and idles fine. still a bit of bog if I hit throttle real fast. It was still slow to idle down but better. I should say the fuel screw is at 2 turns.

When I open PAS to 1.5 it idles down fine. Seems to me this says there is not an air leak.

Still stumped but getting better, any comments??? Go a bit richer on the float?? replace fuel screw O-ring? Just push into garage and allow to collect dust!!???

Thanks, Mike c

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I don't normally recommend this, but try a #50 pilot jet. Your version of FCR carburetor uses different pilot jets than the other FCR's in current models. Set the pilot air screw (PAS) to 1 to 1 1/2 turns or whatever works best and let me know the results.

Also, check any passages that were capped off when removing the air cut valve.

James

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Thanks James, I can't find a #50 pilot jet locally so I need to order one. Currently I have the fuel screw at 2 turns, PAS at 1.5 turns. It idles down much better, but sometimes still hangs at higher idle. Is this ok until I get a 50 or just run it like this?

One other question... Having read many posts, it seems many have gone to a 38 pilot jet instead of going up. I am so confused now and not sure which way is up. I know higher is richer, why am I having such a problem? Ever thought about visiting the "Land of Elvis"?? Just kidding, I do need your expert advise. I am growing ever more bald from scratching my head so much!!!! Help!?

Thanks, Mike c

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You can ride it that way until you get the #50.

The riders using a #38 pilot jets have the pilot air screw nearly closed at ~1/2 turn. The reduced air corresponds with a smaller pilot jet-

#38PJ with 1/2 turn on AIR SCREW (not fuel screw)

#40PJ with 5/8 turn

#42PJ with 3/4 turn

#45PJ with 7/8 turn

#48PJ with 1 turn

etc...

(These are estimates)

James

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