SuzukiSavage.com - Help with carb

JDNewYork

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1999 Suzuki Savage

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Help with carb
02/09/17 at 12:18:30

Hi all,

some ape who owned my bike at some point of its history has made a mess of the carb. Nothing huge and the bike runs fine...however after fitting a Jardine muffler it definitely needs a rejet.

Got in touch with Lancer and got the Jetset but when it came to removing the float bowl was when I realized the mess. The ape has completely stripped one of the 4 bolts that fits the float bowl to the carb...infact on further inspection i think he has actually used the wrong bolt (possibly a little too big).

Unless advised otherwise I am guessing I need to replace the whole unit in order to do the necessary jetting. If so....

1. does anyone have a carb in good condition for sale

or

2. what carb (upgrade) should be bought new? Aside from the muffler everything is pretty stock so not looking for a particularly performance upgrade but if there is something that is worth the money I am always happy to level up.

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« Last Edit: 02/10/17 at 05:42:09 by JDNewYork »

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Kenny G

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Re: Help with carb
Reply #1 - 02/09/17 at 12:34:08

JD,

Take a small vice grip pliers and lock it on the questionable bolt and remove it. Use the same procedure to remove the other 3 bolts. Replacing the carburetor is quite expensive. You can find good stainless steel, Allen Head replacement machine screws at ACE Hardware and may other sources.

Quite possibly Dave on the forum still has a complete set of Allen head screws that he can sell you.

Good Luck!,

Kenny G

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Help with carb Reply #2 - 02/09/17 at 13:06:59 You could live with it if you can remove the bolt or you could PM Wordet 11 He has a stock carb for sale in the market place for $150 with cable ,extra jets an hoses,off a 2002 .I just got some parts from him that arrived today ,he was a pleasure to deal with!(new carb from Suzuki is over $500 )
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JDNewYork

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Re: Help with carb
Reply #3 - 02/09/17 at 13:11:06

Kenny G wrote on 02/09/17 at 12:34:08:

JD,

Take a small vice grip pliers and lock it on the questionable bolt and remove it. Use the same procedure to remove the other 3 bolts. Replacing the carburetor is quite expensive. You can find good stainless steel, Allen Head replacement machine screws at ACE Hardware and may other sources.

Quite possibly Dave on the forum still has a complete set of Allen head screws that he can sell you.

Good Luck!,

Kenny G

The other 3 bolts came off without issue actually (annoyingly it was this one which was the last I attempted to loosen.

I actually have a new set of the 4 bolts as I have already tried using regular pliers to grip the bolt (and I was expecting that after my 'success' I would simply replace all with fresh OEM bolts.

I dont have any really small vice grip pliers but maybe its worth investing in some to give this a try.

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Kenny G

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Re: Help with carb
Reply #4 - 02/09/17 at 13:28:31

JD,

The mini vice grips only cost a couple of bucks.

What ever screws that you use, anything is better than the OEM screws, put some Never Seize on the threads before reassembling the carb. If you don't have a set of Japanese Industrial Standard screwdrivers (aka as JIS screwdrivers) it would pay to by a set if you are going to tinker with motorcycles.

https://www.mcmaster.com/#jis-(japanese-industrial-standard)-screwdrivers/=16...

Kenny G

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JDNewYork

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Re: Help with carb
Reply #5 - 02/09/17 at 13:41:31

Kenny G wrote on 02/09/17 at 13:28:31:

JD,

The mini vice grips only cost a couple of bucks.

What ever screws that you use, anything is better than the OEM screws, put some Never Seize on the threads before reassembling the carb. If you don't have a set of Japanese Industrial Standard screwdrivers (aka as JIS screwdrivers) it would pay to by a set if you are going to tinker with motorcycles.

https://www.mcmaster.com/#jis-(japanese-industrial-standard)-screwdrivers/=16...

Kenny G

A good point Kenny, and I do have a set of JIS screwdrivers (I am guessing a prior ownder did not!)

Wasnt aware of the hatred of OEM bolts etc!! but thats interesting and good to know...I just went the OEM route as I wanted to make sure I was using the exact match bolts....I am always a little scared I will make the wrong choice of 'aftermarket' bolts/screws especially when working with Japanese motors but I can definitely see the advantage of using hex bolts as you recommended.

I will get a small pair of vice grip pliers and report back!

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28888 L.A. California Gender:	Re: Help with carb Reply #6 - 02/09/17 at 13:47:02 Goto the tech section index, look up carb specs, skip all the way to the bottom.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Help with carb Reply #7 - 02/09/17 at 13:47:53 Drill the head off the bolt. Then with the bowl removed you'll have plenty of room to remove the shank and threaded portion.
Back to top	A life-time student of motorcycling. LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG IP Logged

LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10668 Oklahoma Gender:	Re: Help with carb Reply #8 - 02/09/17 at 16:58:27 I have sets of all of the 4 top, 4 bottom & the 3 side cover screws on the stock CV carb; stainless steel, allen head. PM or email me if you are interested. I also have a CV carb if you need one. (Or a Mikuni VM Performance Carburetor if that strikes your fancy)
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justin_o_guy2

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Re: Help with carb
Reply #9 - 02/09/17 at 17:03:18

After the other three are out , twist the bowl, loosening the last one. AFTER you've tried everything else, because that's probably gonna wreck the gasket.
Getting the other three loose often relieves some tension on the last one.

If all else fails, a Dremel to slot the head for a screwdriver,
If that's a bust, take the head off , flatten two sides of what's poking up, and get the vise grips after it.
Don't forget about penetrating oil,

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Dave

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Re: Help with carb
Reply #10 - 02/09/17 at 18:17:57

justin_o_guy2 wrote on 02/09/17 at 17:03:18:

After the other three are out , twist the bowl, loosening the last one.

Don't try to twist the float bowl.

The bowl sits into a recess in the carb body.....and you can't twist the bowl as it has a brass tube for the fuel enrichment that extends down into a hole at the front of the float bowl.....and you have floats and the arms holding the pivot point all sticking down into the float bowl.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Help with carb Reply #11 - 02/09/17 at 18:22:30 Sorry,, forgot about that..works for other things.. Thanks Dave.
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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1452	Re: Help with carb Reply #12 - 02/09/17 at 18:49:41 Left hand drill bits.
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LANCER

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Re: Help with carb
Reply #13 - 02/09/17 at 20:25:53

I vote to cut or file a straight slot that will fit the largest flat blade screw driver you have, then try to unscrew it.
If that does not work then cut the head off, remove the float bowl, and then work the stub you have left.
Be sure to soak it good in penetrating oil first, several times throughout the day and maybe the next day. Keep it wet with the oil. Then try it again.
Don't forget to tap it with a hammer which MAY loosen it.
Actually, use the oil and hammer to start with.
If all that still does not work...send the carb to me and I will give you some credit toward another CV or VM. Just a thought.

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ohiomoto

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Re: Help with carb
Reply #14 - 02/09/17 at 20:47:11

I actually have two carbs for sale.

That said, you'll get that bolt. You'll have no problems with the carb as long as it's only the head that's stripped and not the actual threads. Plenty of good suggestions here.

I've always been able to get them with vice grips over the years. (Lot's of jetting when I use to race motocross and plenty of stuck bolts.)

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