SuzukiSavage.com - New exhaust, filter, jetting. Observations.

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New exhaust, filter, jetting. Observations.
07/24/17 at 11:48:15

This past weekend I did some work on our savage. The craziest thing is that it had a 230 main jet in it. I thought at first that the brand of jet could have been different meaning the numbering wouldn't be the same as mikuni but no, the hole in the 230 jet was massive. I honestly can't believe the bike ran with that jet. I swapped in a 155, used 2 #4 spacers on the needle, and left the pilot jet alone. I put on a sportster muffler I got from a friend (unfortunately it was missing the baffles and is absurdly loud) and I did the Oldfeller filter mod.

The bike is a whole new animal. Revs and makes power much higher, carries my 200lbs to highway speed in 4th, and will pull to 85mph relatively easily. It does have a pretty serious pop on decel, I haven't readjusted the idle mixture after re-spacing the needle. And I also notice its got a bit of an inconsistent surge at cruising throttle. I will probably look for a baffle Dyna muffler then continue messing with the jetting to get it just right. So far I am very impressed with the power this bike makes after these simple mods.

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ero4444 Full Member Offline weekender Posts: 176	Re: New exhaust, filter, jetting. Observations. Reply #1 - 07/24/17 at 13:52:01 great update - thanks. I am excited to try a rejet to match the Dyna myself. Hope I can find where-ever I put them.
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IslandRoad Serious Thumper Offline It doesn't vibrate, it purrs! Posts: 1147 The Kiewa Valley, Australia Gender:	Re: New exhaust, filter, jetting. Observations. Reply #2 - 07/24/17 at 16:57:34 It sounds like the previous owner worked on the carb and mixed up the air jet from the top of the carb with the fuel jet from the bottom of the carb. Others on this site have reported a similar experience.
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IslandRoad Serious Thumper Offline It doesn't vibrate, it purrs! Posts: 1147 The Kiewa Valley, Australia Gender:	Re: New exhaust, filter, jetting. Observations. Reply #3 - 07/24/17 at 16:59:17 And ... a baffled muffler, as you have planned, should aleviate most of the other systems. The Savage doesn't perform well with an open pipe ... so I have read on here
Back to top	S40, 2014, Dyna, Raptor, 52.5/152.5, spacer mod, sea level, cat-eye LED tail light, bullet style halogen turn signals, 'Superbars' with custom 40mm risers, modified stock seat, Metzeler tyres. IP Logged

IslandRoad Serious Thumper Offline It doesn't vibrate, it purrs! Posts: 1147 The Kiewa Valley, Australia Gender:	Re: New exhaust, filter, jetting. Observations. Reply #4 - 07/24/17 at 17:00:28 Oh, one last thought. Did you install the brass washer along with the main jet. It's important
Back to top	S40, 2014, Dyna, Raptor, 52.5/152.5, spacer mod, sea level, cat-eye LED tail light, bullet style halogen turn signals, 'Superbars' with custom 40mm risers, modified stock seat, Metzeler tyres. IP Logged

metalbrian45 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 17	Re: New exhaust, filter, jetting. Observations. Reply #5 - 07/24/17 at 17:10:37 IslandRoad wrote on 07/24/17 at 17:00:28: Oh, one last thought. Did you install the brass washer along with the main jet. It's important Which brass washer?
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2775	Re: New exhaust, filter, jetting. Observations. Reply #6 - 07/24/17 at 17:39:39 Yep, that 230 should be in the top of the carb. I bet you find a 155 up there!
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: New exhaust, filter, jetting. Observations. Reply #7 - 07/24/17 at 19:27:29 230 (6mm) is the large air jet on top ,the brass washer holds the needle jet(the cylinder with the holes) up in place when you screw in the main jet. You can return the Dyna muffler to stock by driving a 1 1/4 " freeze plug half way down the muffler from the inlet end.
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IslandRoad

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Re: New exhaust, filter, jetting. Observations.
Reply #8 - 07/24/17 at 21:36:26

metalbrian45 wrote on 07/24/17 at 17:10:37:

IslandRoad wrote on 07/24/17 at 17:00:28:

Oh, one last thought. Did you install the brass washer along with the main jet. It's important

Which brass washer?

I'll take that as a 'no'. Wink

Just to add to what Batman said, there's supposed to be a washer that sits around the thread of the main jet - like a spacer. I think without it you get too much fuel from that jet.

While we're on the subject, you might want to remove the idle mix screw (carefully) and check if there is a spring, a tiny washer, and a very tiny o ring on there. It's easy to lose and will cause frustrating symptoms while tuning if it's not there.

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S40, 2014, Dyna, Raptor, 52.5/152.5, spacer mod, sea level, cat-eye LED tail light, bullet style halogen turn signals, 'Superbars' with custom 40mm risers, modified stock seat, Metzeler tyres.

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metalbrian45

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Re: New exhaust, filter, jetting. Observations.
Reply #9 - 07/25/17 at 06:11:47

Ok things are starting to make sense. I probably got the jets switched around when I took the carb apart to clean it. I also remember a brass washer that I couldn't figure out where it came from when I was reassembling. It's somewhere on the carb. Looks like I am taking the carb back apart to put everything back in place. I need to swap the pilot jet anyways since I haven't messed with it yet. Thanks for all the help guys!

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: New exhaust, filter, jetting. Observations. Reply #10 - 07/25/17 at 06:50:12 It's okay to just stick stuff wherever you can make it fit.. If you're playing with Mr. Potatohead! Carburetors, ehh, notsomuch.
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batman

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Re: New exhaust, filter, jetting. Observations.
Reply #11 - 07/25/17 at 08:35:05

The surge at cruising is probably due to the fact that you have no baffle in the Dyna,this is why straight piping doesn't work, it causes a sag in the torque curve at part throttle openings .You need to restore the baffle with a soft/freeze plug ( used to plug the water jackets in the sides of auto motor heads,that you can buy at any parts store)as no amount of carb tuning will cure the sag.

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Old School Bobbers YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 4	Re: New exhaust, filter, jetting. Observations. Reply #12 - 07/28/17 at 11:13:11 Take a look at " 6 SIGMA " jetting kits, Ive used them in a number of bikes including 4 X S40s. The only thing they do not give is a new needle, but the do include a Pilot jet, a number of main jets etc. They also ask a number of questions as to where you live before calculating what jets you need.
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