Hi Guys, I am going to do the white spacer mod and re-jet this weekend because I just put a Dyna muffler on the bike. I can find plenty of instructions on how to pull apart and work on the carb, but I can’t find any that give the best procedure to remove and replace the carb from the bike. So here are my questions.

1.To remove the carb, do I just loosen the intake pipe clamp but leave the intake pipe attached to the head. Or is it better to unscrew and remove the intake pipe with the carb?
2. Again for the other side of the carb, do I just loosen the clamp around the airbox outlet tube and remove the carb, or is it best to remove the entire outlet tube with the carb. I am thinking it probably doesn’t matter, but which is the easiest to do?
3. If my stock petcock is working correctly can I leave gas in the tank or do I need to drain it when I remove the fuel supply line and the vacuum line from the carb? Or do I actually need to remove the tank to get the carb off.
4. Also once I finish the spacer mod, if I want to re-jet again in the future, can I do that while the carb is still on the bike, by just removing the float bowl from the bottom of the carb?

Because so many users here have changed their jets multiple times there must be a consensus on the steps needed to get the carb off.  Thanks

Loosen band clamps, rotate carb for easier screw access. Replace funky cheesy chintzy little factory screws with stainless steel allen head screws. No need to remove the carb unless it needs to be dipped or have the internal passages pressure flushed with aerosol carb cleaner.

Have to rejet mine again, pulled the header pipe today and the inside looks like it is full of coal dust. Time to dial it back a couple notches... the choke being unnecessary, and the rather diesel looking smoke were a pretty good tip off as well...

DF0518,

One very important thing (extremely) is to replace the screws with stainless steel or galvanized screws (ACE hardware store has them). The original screws are very crappy and tend to get damage very easy.

There are 2 ways to get to the sleeve to replace the spacers: one is like WD suggested from the top, after removing the tank etc, etc. The other way is by taken the carb out (my preferred method). Either way works. Very important to replace those cheesy factory screws, you will thank us later. You do not have to drain the tank to remove it.

And yes, you can re-jet with the carb on the bike. But like I mentioned above I prefer taken it out completely but, it is your choice.

Suggestion: once there, since you already put a Dyna and are going to re-jet  you should also consider removing the plug on the idle mixture screw. There is a lot of info in the forum on how to do that also. See link below.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1221818822/0#0

The other suggestion is change the factory Petcock for a Raptor

Btw, welcome to the forum  

You don't have to but I did replaced mine (the top ones). The original screws are also cheap metal