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04DRZ400s Jetting help

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I have an 04 drz400s with 3X3 DJ stage1 full RS3 and:

142.5 main jet

25 pilot jet

Keintech extended fuel screw

needle clip on 4th position

i am at 2000 ft ish

When riding at highway speed for an extended period the bike will surge

real bad, sometimes even stalling the bike out. Am I running too rich?

Also, the new extended fuel screw is very loose in the carb and sometimes even falls out.(only about 2-2.5 turns out) Since insalling the fuel screw the carb also leaks fuel out of the fuel screw.

Any advice on proper jetting,as well as my fuel leak, would be appreciated. :)

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Sounds to me like you might have forgotten to swap the spring or o-ring from the stock mixture screw. The spring holds tension on the screw, and the o-ring keeps it from leaking. The spring should go on the screw first, then the small flat washer, and lastly the o-ring. Check the shop manual or an online parts fishe for a diagram. Also seems like your too lean on your main jet. The DJ stage 1 kit doesn't alow for the airbox mod. You should be about at a 155 main, stock pilot with that fuel screw, and clip positon may depend on what needle you have. I highly recomend the JD kit, on the 3rd clip on the blue needle. I run the same setup but with a 160 main at sea level. Good luck!

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I have all of the parts installed with the extended screw.I have lost the washer, spring and o-ring twice and had to order new ones due to the damn thing falling out. As far as jetting goes i will try to order a larger main and try that.I have even tried to put the stock screw back in and it leaks as well.

thnx for your input though.

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Will it even fall out if its only a turn or two out? Or do you run it further out than 3 turns?

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Yes it will eventually work its way out no matter how far in it is. I have the needle that came with the stage1 kit (on the 4th clip) with the BSR carb.

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Hurumph...you got me. Other than having the wrong screw in there I've never seen that happen. Weird. Maybe the threads in the carb are wasted. Sorry man!

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