ThumperLife wrote on 08/09/24 at 08:22:44:Well... after confirming with the '07 carb that the '97 bike runs great and that the '97 carb has been my issue, I have soaked that carb body, confirmed that all passageways are clear, fitted it with all new jets based on how the '07 is jetted, put the '97 carb back on the '97...
and it still runs horrible. spits soot. barely idles... it's actually worse than it was the first time i cleaned it.
literally with the carbs side by side, the only thing i noticed is that the vacuum slide's spring is about 30% taller for the '97, but i don't know what that would have to do with the way it idles.
I guess the '97 carb is junk and I'll get a performance carb.
Unbelievable.
ThumperLife - Below a somewhat recent thread from when I installed the Keihin PWK38. Maybe it can give you some ideas and help with jetting.
I think I reference the manifold I used (it’s a Mikuni but it fits like a glove on the Keihin PWK38). I’ll reread my own post and if I didn’t note the manifold, I can find a link to it from when I bought it. For these cheap knockoff carbs, I do buy and use cheap knockoff jets.
To cut to the chase and without reading my thread, I’d suggest starting with:
Pilot Jet: #32 or #35 (#32 is a little cleaner and more stable idle once dialed-in in my opinion - try 1.5 turns out on the mix screw). Note: The mix screw is opposite the stock CV carb - turning it clockwise is richer).
Main Jet: Start with a #125. See my thread on this one. It’s been a bit more of a challenge for me.
Needle clip - try the middle groove first. I ended up moving to the 2nd from the top (leaner). This one is also tricky and your needle may be different than mine (life is like a box of chocolates with these carbs - you never know what you’re going to get).
You’ll have to decide if you want to use the stock air box or do some other air intake. You’ll see I tried both and I’ve settled in with a UNI pod filter connected directly to the carb.
You’ll also have to come up with a throttle cable mod or maybe Lancer can hook you up with a cable that he sells with the Mikuni VM36 slide carb kit. It’ll work on the PWK38 too.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1714330191