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Found 7 results

  1. Hello Riders! The small spring attached to the jet needle stopper doesn't hold in position, and sometimes the thin washer also comes out of the whole needle assembly. Though the needle, white plastic washer, thick metal washer and stopper seem to remain in place. This happens when i turn the carb upside down a couple of times (to make sure the needle is moving) the needle-washer-spring-stopper assembly disassembles. Sometimes the spring comes loose and is miraculously sitting in the upper diaphragm (as shown in first pic) while the rest of the components somehow keep together. Sometimes the thin washer on top separates out from the 5 component party. Does this cause problems, if yes how do i fix this flimsy penta gang from falling apart during turbulent rides? Last time i came back from a ride up in Big Bear the carb wasn't performing well on inclines, but was perfectly fine on level ground - then i came home and opened the carb to find the small spring sitting loose in the upper diaphragm. Or maybe it was just because i couldn't adjust the fuel mix screw (was impossible to reach, am getting an extended one). 2nd pic: I noticed the small O-ring below the carb cap was missing, is it critical? I placed a run down O-ring from my older fuel mix screw assembly. Are there local parts shops which stock such teeny weeny components around in Southern California (San Diego). thanks, K
  2. Hello Reader, I've been struggling with this issue for a year on 2005 Suzuki DRZ 400s. Configuration: Mikuni BSR36 carburetor (rebuilt 4 months back), brand new top end, new stator coil & battery Modifications: 3X3 air box mod, yoshimura slip on rear exhaust, 4 gallon fuel tank with manual petcock, added kickstart & TKC80 tyres Problem: I took my bike to hilly trails near the Big Bear national park in California in Dec'20. The point where we parked our trucks and took the bikes out was ~3.5K feet above sea level. My bike was starting fine with just button start, and also running fine around the parking area. When we started ascending the trail, which would be another ~400 feet the bike started to struggle to keep alive and whenever i felt it go sluggish i'd give more throttle. This helped and the bike would ascend, but my confidence was getting eroded. Then at a point where there were rocks and i had to rev the bike to climb them the bike couldn't climb over, and as my grip loosened on throttle the engine died. I bump started the bike by using the decline, and turned around to start ascending. After a mile we reached a plateau and here i stopped and pressed the kill switch, to test the kick start reliability. Ok, so i pulled out the choke, adjusted the idling switch (but couldn't twist the fuel screw) and ended up kicking 15-20 times before it finally started. Now i just turned back to the parking area since i couldn't risk getting stuck in the labyrinths of criss cross off-road trails ahead. When i reach the parking area, the bikes back to perfect performance. I can button start it and ride it around the same area with no issues. What gives? I checked with my fellow rides, some suggested float valve, some said something else but i haven't really take the bike apart since then. So here i am, trying to figure if it's the jetting, air fuel screw or float valve or something else? Any help would be much appreciated. Oh, and wish ya'll a great riding year of 2021 ahead!!! Kamal
  3. I was out for a ride the other night, just puttering around the local back roads (what I mostly do) on my 2017 DRZ400S. The bike is stock with the exception of the 3x3 mod and JD Jetting kit (their recommended settings). The bike had been running very well. I had sorted out the few issues after doing the 3x3 mod and was enjoying the bike a great deal. Most of the way around the loop I was riding (only about 45km) I pulled off a side road onto a minor highway - no traffic, so I ripped up through the first few gears (bouncing off the rev limiter once) before slowing to about 90km/h. While downshifting for an upcoming traffic circle the engine did not "blip" like I expected, it sort of bogged. As long as the revs stayed up I was able to accelerate (modestly by this time). At this point I'm still beyond pushing distance from home. I managed to make the lights and didn't need a full stop until almost home. I stalled coming from a stop and found that if I rolled the throttle on "very" gently I could get moving and stay moving. At home in the driveway I confirmed the engine would die if the throttle was opened from idle with any sort of enthusiasm, and then seemed reluctant to start again. Before I start pulling things apart I though I'd ask if anyone out there had similar experiences. Bike is 2017 S, stock exhaust, 3x3 with JD's kit at their recom. settings - ran very well until that WOT rip. Gas is local Chevron 94. (though I did tank up at the start of the ride, just over a half a tank. Gas in tank was last fall's gas (94 again) with stabilizer added when parked for winter in November. I've never had issues with this suppliers gas before. Last bog issue was just after the jetting upgrade. I buggered the plastic needle retaining clip in the slide (a $110 lesson). A loosely bouncing needle isn't a good thing. At that time, the issue made itself known very soon after I'd put everything back together. I've put a fair number of kilometers on since fixing that issue so I'm not immediately inclined to think it's the same thing. (unless I "almost" bodged it again and it's taken until now for a weakened retainer to toast itself...?) I will check stator/battery/RR to rule out electrical issues before I pull the carb to see if it rattles. If you read this far, many thanks!
  4. Hello Readers, I've been struggling with this issue for a year on 2005 Suzuki DRZ 400s. Configuration: Mikuni BSR36 carburetor (rebuilt 4 months back), brand new top end, new stator coil & battery Modifications: 3X3 air box mod, yoshimura slip on rear exhaust, 4 gallon fuel tank with manual petcock, added kickstart & TKC80 tyres Problem: I took my bike to hilly trails near the Big Bear national park in California in Dec'20. The point where we parked our trucks and took the bikes out was ~3.5K feet above sea level. My bike was starting fine with just button start, and also running fine around the parking area. When we started ascending the trail, which would be another ~400 feet the bike started to struggle to keep alive and whenever i felt it go sluggish i'd give more throttle. This helped and the bike would ascend, but my confidence was getting eroded. Then at a point where there were rocks and i had to rev the bike to climb them the bike couldn't climb over, and as my grip loosened on throttle the engine died. I bump started the bike by using the decline, and turned around to start ascending. After a mile we reached a plateau and here i stopped and pressed the kill switch, to test the kick start reliability. Ok, so i pulled out the choke, adjusted the idling switch (but couldn't twist the fuel screw) and ended up kicking 15-20 times before it finally started. Now i just turned back to the parking area since i couldn't risk getting stuck in the labyrinths of criss cross off-road trails ahead. When i reach the parking area, the bikes back to perfect performance. I can button start it and ride it around the same area with no issues. What gives? I checked with my fellow rides, some suggested float valve, some said something else but i haven't really take the bike apart since then. So here i am, trying to figure if it's the jetting, air fuel screw or float valve or something else? Any help would be much appreciated. Oh, and wish ya'll a great riding year of 2021 ahead!!! Kamal
  5. While troubleshooting the carb last week I noticed the torsion spring that loads the throttle wheel (to keep the throttle valve closed) wasn't connected to anything in particular. Both ends of it were just hanging in space rather than resting against a stop. Needless to say the spring couldn't put any force on the throttle plate. I hooked the ends up around/against in what seemed like logical locations. This resulted in a positive closing force on the throttle plate. However, I'm not sure if it's enough pressure or not. So CV carb experts out there... How much pressure is enough? (do I need to take and extra turn in the spring before letting it rest against the stop, or is just enough to close the throttle plate enough?) I could find no references to this, and the part is not called out in the parts drawings to I assume it's a "factory stet" part that's not meant to be fiddled with. (I have no idea why it was loose in the first place...)
  6. Ok guys well my bike isn't running right at all here some info on whats going one. About 3 weeks ago i was riding my bike and everything was fine shut it off and when i restarted it is stareted to run like crap. It pops and boggs at most throttle positions. I have removed the carb and made sure is was clean and good to go. I have been into it 3 tims in the last 2 weeks and i even cleaned it in a sonic bath. still same exact problem. I have checked for leaks while running by spraying carb cleaner around the entire carb and boot etc, no changes. My bike: -2006 DRZ400s with a stock Mikuni BSR36 Carborator My mods are: -CW BBK -Yoshi RS2 full system -K&N air filter I have the JD carb jet kit. the jets are: -Main Jet 155 -Pilot jet 25 -Starter jet 62.5 -Using the blue needle with the clip in the middle position So I installed the CW BBK about 3 years ago and along with the exhaust and the jet kit so it has about 9,000 miles on it and it ran MINT the entire time until now. I have also linked a video to this thread showing me slowly rev and hold throttle from idle,1/8,1/4 and 1/2 throttle. the rattling in the video is from my lift i use just fyi. The stator was replaced last season due to non charging and was replaced with a new OEM unit. Just for shits and giggle I have another known good stator so i swapped it out to see if that was a problem and still have the same issues. So any idea would be appreciated! Thanks guys
  7. 2017 DRZ400S (black and blue - I wonder if that should have told me something...) A bit of background: Did the 3x3 mod using the JD Jetting kit and the Keintech extended fuel screw with the following setup: JD blue needle, clip in 4th from top position 155 main jet pilot jet stock (22.5) with the Keintech extened fuel screw turned out about 2 1/4 turns. Other than the carb mod the engine is stock, the exhaust is stock and it's got about 1900km (less than 1200 miles). Last week (coolish 11-13C) the bike ran very well (as I said in the master 3x3 post, it woke the bike up). Great throttle response from idle to WOT. Last evening (a very unseasonable 23C) the bike started but died when I blipped the throttle. WHAT!!?? Restart and same thing. Restart and ease the throttle open slowly. It bogged just off idle and then ran fine. If I kept out of the near idle area it seemed like it did last week. Once it got back close to idle it bogged and stumbled. Not a good traffic response. (died on highway starting from light...paddle frantically to shoulder. Started right up and was able to take off with a more than usual (for me) handful of revs. (Ride home last night from coffee with the DS boys I did get to 125km on the highway without issues. Just the whole getting started fuss. Oh, and a constant, small throttle opening at low speed (just up off the idle), the bike bucked like it was stalling but the forward momentum kept it from stalling. Unnerving to say the least. Today I confirmed the fuel screw had not "wiggled" itself loose - it had not. I fiddled with it (according the the various instructions on this site and elsewhere) and couldn't get rid of the stumble. I did get it to where, if I was very deliberate, I could slowly increase the speed off idle and get over the "stumble bump" A test ride again had me stalling from a stop. A generous handful of revs and clutch slipping got me underway, but this isn't normal, So, what's changed? I don't honestly know. I did refuel before last week's satisfying ride, putting about 50km. (the tank was about 2/3 full and I topped it up) Chevron 94 (pump says no ethanol) is what I always put in, and what as in it previously. Before last week's ride the bike had sat, unridden since early March. (about a month). So carbahooter gurus... any ideas? Did my good gas go bad? My karma got twisted, blinker fluid leaked in? Tomorrow I'll drain the gas from the tank and the carb and start with fresh 94 while I await the forums wisdom.
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