Thanks for the input. Couple questions/comments...
1. I heard something about an impact screwdriver set from harbor freight. Is this something I should explore or could I do more damage than good? How to I get these stubborn internal screws loose without damaging them?
2. I will test the fuel flow with and without the inline filter. Maybe my petcock needs to be rebuilt/replaced.
3. When I purchased the bike it had an aftermarket pod filter on the carb and an aftermarket exhaust. I do not know what mods were done to the carb (ie rejetting). It ran strong for months after I purchased it. Should I be concerned about this?

Thanks again for the input guys.

So much I don't know. Never heard of JIS. Thank you. I am going to pep boys tonight for some spray berrymans and I will look for JIS screw drivers. Thanks again!

File down the tip of a #2 Phillips screwdriver until it seats snuggly in the JIS screw. It works a treat, even on screws with a damaged head.

Island road is correct it can be done ,I would advise you to use a hand file to reshape the point ,a grinder would tend to over heat the point and it would lose it's hardness.     You might try Sears (craftsman tools)

I put them in the screwdriver and poke them up against the bench grinder. Only takes a couple of seconds. I've put them in the impact and seen no problems.

Hoodlum333 wrote on 02/20/17 at 12:58:56:


Inline fuel filters can be problematic.  The stock fuel line is relatively small, and the problem with the fuel filters is the nipple end has a really small hole through it....an air bubble can get trapped in the small passage and block the flow of fuel....the air is trying to go up - while the fuel is trying to flow down - and nothing flows.

This issue has been discussed before...some people can use the inline filters and never had a problem, some never get them to work, and some folks get them to work when first installed - then they cause problems later on and the problem is hard to troubleshoot....as it has been working OK for many miles.

Here is a link to the fuel filter discussion thread in the Tech Section.  Hondalavis tried one and it worked for a while...then didn't.  Go to post #17 to read about his issues.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1211846392


In my opinion, the problem with installing a filter - is that the Suzuki Savage uses gravity to get the fuel to flow.  A gallon of gasoline weights 6.07 pounds per gallon - or about 45 pounds per cubic foot.  This means that each 3.17 feet of height results in about 1 pound per square inch of pressure.  I don't have a bike here to measure - but if there is about 16" from the top of the fuel tank to the float bowl.......there is only 0.4 psi attempting to push the fuel past the float needle.  As the fuel level drops the pressure becomes even less.  The result is that adding a restriction in the fuel line (filter with small openings in the nipples) is a very bad idea......look at the nipples on the petcock and carb and you will see that they are made of very thin tubing and don't reduce the flow diameter below the size of the rubber tubing - while the plastic filters are made of thick plastic and do reduce the opening size dramically.  At these small diameters, the changes in the area of the tube is drastic.  The stock hose is 9mm, which is a diameter of 0.354 inches and has an internal area of 0.0986".  A 5/16" hose is the closest inch size, and that drops the internal area to 0.0767 sq. in - which is a reduction of 22%.  If you reduce that size to 1/4", the area drops to 0.0491 sq. in. - which is a reduction of 50%....you have cut the internal flow area in half!  If you are installing 1/4" fuel filter....and it has thick plastic nipples - it will be even worse....and it can easily trap air bubbles that cause the fuel to stop flowing.

Agreed.