How Do I Rebuild Suzuki Carburetors?

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A carburetor in your Suzuki helps blend air and gas as part of the combustion process in your engine. Over time the carburetor can become filled with debris and other substances, leading to poor performance in your Suzuki engine. In order to solve this problem, you need to completely rebuild the carburetor. Doing the rebuild will take you an afternoon to complete, and the replacement parts are readily available.

Things You'll Need

  • Socket wrench
  • Screwdriver set
  • Carburetor cleaner
  • Gasket
  • Carburetor jets
  • Putty knife
  • Use a socket wrench to remove the bolt that attaches the throttle cable to the carburetor. Pull the cable away from the carburetor. Turn the fuel petcock to the "Off" position and disconnect the fuel lines from the carburetor.

  • Loosen the bolts attached to the intake clamps with a Phillips head screwdriver. Lift the carburetor from the Suzuki.

  • Remove the bolts attached to the carburetor bowl with a socket wrench. Remove the bowl from the carburetor. Take the gasket out of the bowl and discard it. If the gasket has blown, it will be stuck to the bowl, and you may need a putty knife to remove it.

  • Remove the pivot pins and the floats from the float needle valves and away from the carburetor. Use the Phillips head screwdriver to remove the jets from the carburetor.

  • Clean the jets thoroughly with carburetor cleaner, making sure you get rid of any debris present in the passages. Reattach the jets to the carburetor and secure the jets in place by reattaching the screws.

  • Place new pivot pins and floats onto the float needle valves. Attach the retaining pin onto each pin. Place the new gasket into the bowl. Place the bowl back into the carburetor and secure it in place by reattaching the bowl mounting bolts.

  • Place the carburetor back onto the Suzuki and secure it in place with the bolts. Reconnect the fuel lines and throttle cable into the carburetor. Turn the fuel petcock to the "On" position.

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References

  • "Suzuki DR-Z400E, S & SM 2000-2006"; Jay Bogart; 2006
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