There should be a spring, o-ring, and washer behind the pilot screw.  See parts 41-44. Part 45 is the brass plug installed by the factory that you have to remove to adjust the pilot screw.

https://www.partzilla.com/catalog/suzuki/motorcycle/2005/boulevard-s40-ls650/...

Did you find a spring, washer, and o-ring in the hole?  

Maybe your spring and washer are mangled up in there preventing you from treading the screw in further where it needs to be.

I've also had the hole weep gas when I forgot to put the o-ring in there on the screw.

PS - I think this discussion belongs in Rubber Side Down.  Maybe ADMIN can crop and move it over there.  (I probably stretched the rules with my comments about aftermarket kits - my bad.)

Bohica88 wrote on 08/15/24 at 11:04:50:


couldn't find good pics but this one shows it in general

That’s good, but you still have to figure out what’s preventing the screw from going in further.  If you don’t see something lodged or stuck down in the hole (like a crushed old spring and washer), I would remove the carb to see if the threads are stripped and preventing the screw from going in further (you may have to retap the threads).  There could also be a piece of an old screw stuck in there and you’re just ramming your good screw up into it.  I mention this because I completely ruined a carb recently when I tried to remove a stuck/seized screw.  I ended up getting another used carb and rebuilt it with a combination of new parts and using the better used parts from each carb.

Bohica88 wrote on 08/20/24 at 18:42:19:


I sent you a pm so you can simply reply back.