Did someone put an extra part in there? (Now with pics)

[mjn12]

As I was getting ready to checkout with a shopping cart full of o-rings and seals for my carbs, I noticed that there was a washer under the clip on my needles that I didn't put there and doesn't show up on the diagram.

My question is, how many plastic washers/spacers should be under the clip on the needle for a '00 stock.

My bike came from the p.o. with Spring seat over the clip and the plastic spacer 'donut' and one thick plastic washer under the clip.  In the pics in the how-to's and here :http://www.angelfire.com/mt2/mikesgs500/rejetting/
as well as in the bike bandit/ron ayers diagrams I see only 1 plastic spacer under the clip, not 2. 

How mine came ("stock")

||===E====D====W=====-->

|| spring seat
E e-clip
D- donut
W - thick nylon washer (little less thicker than the donut)

[makenzie71]

It was done to raise the needle to richen the mix from 1/4 to 3/4 throttle.

[mjn12]

done by suzuki or done by the po?

I'm running way rich in mid-high range throttle with 125 mains no #4 washers, wondering if this is why

I'd understand if the p.o. did this to compensate for lean jetting from factory but now that I've rejetted I wouldn't need it, unless its factory that is.

[makenzie71]

Who knows who did it...who cares who did it?

If you're too rich in the mid, pull the spacers out.  Does the bike run good at WOT?

[mjn12]

bike runs ok until the plugs fowl.  It can idle all day and plugs are clean but when I go out for a ride and bring it into the mid/high range I come back with very black plugs after only half an hour or so.

[makenzie71]

Pull the shim out.  If it runs fine at WOT and idles then everything else is dandy.

[mjn12]

I'll give it a shot when I replace my clutch cable this afternoon.  If this fixes my problem I can't even begin to explain how much trouble those two little pieces of plastic have caused me

[mjn12]

This is how it came from the p.o.


I pulled that lower (rightmost) washer and the bike turned into a whole new animal.  I get little idle hang (maybe I can richen that up with the air screws) but it pulls much better at the lower end and throughout. waiting on it to cool to see if the plugs are white as a ghost.

UPDATE: Plugs looked *slightly* lean - just slightly whiteish on the top maybe I can get rid of this with the mix screws

If that washer is in fact stock and it needs to go back in someone please tell me

[Egaeus]

I've never seen that thing before.  It's not stock, and too thick.  It is definitely at least contributing to your richness problem.  You might try a #4 washer instead of that donut, 0.5 mm thickness or so.  I have some if you need a couple.

[mjn12]

wrecentwryder hooked me up with some a few months back, those are in there now and the bike is running 1000x better without those extra spacers.  So much pain - 6 months of troubleshooting. $200 at the shop and they iddn't even catch those things.  Seems to be a lot better, looks like I'll be riding instead of wrenchign for a change.

Just so happens to be finals week when I figure it out.  Stuck inside the library staring out at the awesome weather.  Just a few more days and I'll be on the road.

[Egaeus]

You're doing better than me.  I still haven't gotten mine working exactly right, and my JB Welded gas tank finally sprung a leak.  I guess I'm going to have to have a mismatched tank and plastics for a while....

[Wrecent_Wryder]

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