JEastonjr wrote:
Moto, Your not too far away from me. Maybe we should plan a meeting.

Yeah, let's connect. Let me work on it this week and we'll pick a sunny Sunday if that works for you.

Well, here is a quick update...

I replaced the plugs, took the carb off and cleaned it well - not soaked or sparkly clean, just in the holes and the throttle body - rechecked the float (still not totally convinced it's right) and rejetted the carb to....

Main - 170 (may go back to 172.5)
Pilot- 35 (I'll get back to this in a minute)
PMS out 3.5
Needle 4th clip

No popping with the 172.5, hesitation and vibration is at a minimal but still there same throttle positions.

For kicks and giggles I put the 170 in and it started popping on light decel.

Million Dollar Question!!!
Is the DJ Pilot 37.5 the same as the Mikuni 37.5?

I am resolved to go back to the 172.5 main (overall it ran much better- no popping, hesitation or hiccuping), keeping the needle on the 4th groove and going to the 37.5 pilot IF my float level turns out to be ok.

The only issue I had was starting it cold. Warm - fine. Cold - as soon as the enricher went in, the bike shut down.

No. The DJ and Mikuni 37.5 are not the same.

silver_fox wrote:
No. The DJ and Mikuni 37.5 are not the same.

Well, that explains a lot...

I have an email in to jetsrus.com, would you happen to know what the correct part number is?

Updated my profile....

Current setup

Main- 172.5
Pilot- 40
PMS- 2.25
Needle- 4th groove

Figured out my starting problem was the float too rich. Spent all morning trying to get it right. What a pain in the butt. Still not convinced, but it is as close as I can get it.

I was reluctant, but had a 40 Pilot laying around so I put it in. I feel it is a bit overkill, but it runs better with it COLD than the 35. As soon as I find out what the Mikuni 37.5 part number is, I'll get one. Why not.

I'm done for now playin with this thing. At this point, I might as well own a Harley.

Still open for suggestions if anyone has them. May be open to offers too... jus' sayin'.

motoscooter wrote:
Updated my profile....

Current setup

Main- 172.5
Pilot- 40
PMS- 2.25
Needle- 4th groove

Figured out my starting problem was the float too rich. Spent all morning trying to get it right. What a pain in the butt. Still not convinced, but it is as close as I can get it.

I was reluctant, but had a 40 Pilot laying around so I put it in. I feel it is a bit overkill, but it runs better with it COLD than the 35. As soon as I find out what the Mikuni 37.5 part number is, I'll get one. Why not.

I'm done for now playin with this thing. At this point, I might as well own a Harley.

Still open for suggestions if anyone has them. May be open to offers too... jus' sayin'.


I'm runnung the same setup on my 05, but I went with the clip in the 3rd postion w/spacer and 2 shims. Mine's running really good right now.

I'm runnung the same setup on my 05, but I went with the clip in the 3rd postion w/spacer and 2 shims. Mine's running really good right now.

I noticed you removed your pump from your profile. Did you do it through the article on the clinic or did you just take it off?

did that affect your fuel mileage at all? I have been thinking about doing that too...

bike looks sweet btw...

motoscooter wrote:
I'm runnung the same setup on my 05, but I went with the clip in the 3rd postion w/spacer and 2 shims. Mine's running really good right now.

I noticed you removed your pump from your profile. Did you do it through the article on the clinic or did you just take it off?

did that affect your fuel mileage at all? I have been thinking about doing that too...

bike looks sweet btw...

Thanks yours does too. I removed the fuel pump as described here. My mileage has been between 36 - 40. Closer to 36 as its fun to get on it now.

..ok, so here is another question.

Do you need the fuel filter?

I know a few have removed the whole enchilada, so I was wondering...

With all the changes that I have been making... and making... and making...

I think it might be a good idea to change out the needle valve to the 2.5 from the Change the Float Bowl Needle Valve (and lose your fuel pump) tech article.

Here is my thought process....

One thing that has not been changed or replaced & still connectable to the original shop disaster is the float/needle valve. Knowing what I know now, I believe when they put the carb back together, they set me up with a low float level making the whole bike lean.

With all the changes I made TO the bike (pipes, BAK, etc...) It seems I have created a need for a richer setting on EVERY circuit EXCEPT the needle valve - which controls the float level at the very spot I am at on the throttle. So I wonder if my float is set correct, but not getting fuel fast enough for that that idle/pilot crossover. Everything else pulls off the main to "correct" itself from what I have read on the CV type carbs.

I originally went a little higher on the float, but it wouldn't start very well. Lower served nothing really, except to demonstrate just how important that float level is

So, I am looking at getting the 2.5mm needle valve along with a Mikuni 37.5 Pilot and believe that my issues will be resolved.

Does this make sense to anyone else besides me?

(I must add... in all my tinkering, and riding, and tinkering, and riding - for a day and a half...

I discovered the ONLY time the intensity of that vibration changed was when I changed the float level. After several tweaks, I believe it is correctly set now - did it all on bike too. Will have to cut a vid or something for ya's - and that is where the needle valve being too small idea came to be.)

That 2.5 float valve in the article no longer applies and should have some kind of warning in the article. The float valve to use is the Yamaha Grizzly 3.0 valve. I don't have the part number handy but if nobody chimes in with it I'll try to look it up.

Besides that Suzuki valve was expensive. The Grizzly valve is only about $19.