Lunchbox and Jetting, Quick questions!

[Dirtbox]

Delkevic exhausts are UK legal if you choose the right end can.  The ones that are shorter than 350mm are generally too loud mine is 350mm and is fine.

[Crasm]

Delkevic exhausts are UK legal if you choose the right end can.  The ones that are shorter than 350mm are generally too loud mine is 350mm and is fine.

Ditto!!

Im very pleased with the sound of mine even after 9 months of it

[Jayke]

If either or both of you happen to have a good camera/dslr, if you wouldn't mind could you do a sound test kind of thing? There's one video on YouTube right now and it's kinda bad quality!

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[Crasm]

 just read your first post and checked my haynes manual which makes an interestimg read
Especially when the carb parts diagram dont even show or mention the mid main jet just the pilot and main jet.
Also from what the haynes says , the uk had adjustable needles so we dont need to space them out with washers

And according to the haynes only the american models had the air screws capped off , summet to do with the carbs had to be sealed for emissions purposes in the usa

[adidasguy]

1989-2000 carbs had 2 jets
2001+ carbs have 3 jets

[radodrill]

And according to the haynes only the american models had the air screws capped off , summet to do with the carbs had to be sealed for emissions purposes in the usa

On the GS it's actually a fuel screw as it meters the fuel leaving the pilot circuit, some bikes have an air screw that meters air into the pilot circuit; generally speaking they're both idle mixture screws.

The EPA mandates that all carbureted bikes sold in the US have a brass plug over the mixture screws so that the owners can't mess with it and increase emissions.


And as adidasguy mentioned; the early GS carbs only had 2 jets and that's what's shown in the schematic in the Suzuki service manual, yet they didn't have an update on the carbs for the 01/02 model where the 3-jet carbs were introduced.

[Jayke]

Interesting, for the carb work I'll be following the guides online or a YouTube video or something. Breather came today, only ordered it last night aswell! Hopefully everything will come for about Tuesday as thats when I am planning on doing it.

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[Crasm]

Radodrill - the thing thats pissed me off about it is , i paid 20 quid for my haines manual that states  for the 2001 - 2009 models but yet still doesnt mention the new carbs or anythin about the 3 jets.
Yet the older gs haynes maual was half the price. I feel like ive been conned !!

[Jayke]

I bought one too, never actually noticed though, myself! Quite interesting that they say they cover the newer bikes, but in theory don't. Although from what I see pretty much everything is identical other than the carb, engine wise anyway.

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[radodrill]

Biggest changes I can see in the Suzuki service manual:
96 - new front brake caliper
01 - 3-jet carbs
03 - new front brake master cylinder
03 - Electronic tachometer (no longer mechanical)
03 - new timing pickup and ECU
03 - TPS on carbs
04 - "F" model introduced with full cowling
04 - oil cooler added (only F model)
04 - PAIR system added
06 - Starter button changed; now disables the lights when pressed

Of course the made other minor changes such as connectors, colors etc over the years, but mechanically it's mostly unchanged.



I actually never bought the Haynes manual; but I'm guessing they say it's for the 01-09 because it includes the cowlings etc.

[Jayke]

Biggest changes I can see in the Suzuki service manual:
96 - new front brake caliper
01 - 3-jet carbs
03 - new front brake master cylinder
03 - Electronic tachometer (no longer mechanical)
03 - new timing pickup and ECU
03 - TPS on carbs
04 - "F" model introduced with full cowling
04 - oil cooler added (only F model)
04 - PAIR system added
06 - Starter button changed; now disables the lights when pressed

Of course the made other minor changes such as connectors, colors etc over the years, but mechanically it's mostly unchanged.



I actually never bought the Haynes manual; but I'm guessing they say it's for the 01-09 because it includes the cowlings etc.

Thats pretty cool, kinda wish I had the electric tacho though in a way, as my tacho actually kinda hovers. Say I'm at 6k rpm, itll hover between 5.5k and 6.5k sometimes... Just seems in a 'dumb' way that it isn't tight enough. Maybe theres a fix, not sure! 

[Jayke]

Half way done it seems but can't get any further as the screws for the bottom of the carb are stuck!!!!!

Not sure how to get em out!

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[radodrill]

That's common for a set of carbs that haven't been opened before.  Be sure you're using a JIS screwdriver (not Phillips).  If you have an impact screwdriver, you can try to use that to break the screws loose.  If all else, grip them with a pair of vice-grips (or pliers) and turn them out.

This is exactly why most people replace them with Allen screws; 1) because they're easier to remove and 2) the original screws often get messed up while removing them.

[Jayke]

Yeah they're screwed almost. Managed to get 3 on one and one on the other side. Grrr!

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[radodrill]

Another thing to try is an EZ-out; essentially it's a left-hand drill at one end and a left-hand threaded cone at the other end.  Essentially you drill out the stripped head first then the cone bites in and threads the screw out.

[Jayke]

Looks like a great idea, just don't have one . Having alot of trouble. Looking like I can't get them out. Argh!:(

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[radodrill]

IIRC vice grips did the trick for me

[Jayke]

I have a set of them but they are big, tried to lock them on but they just slip off everytime.

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[Jayke]

What a mess. I feel like a right idiot

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[Jayke]

What do you think about this? The gold circle things not sure what they're called, the left one is open a tad, all the time?

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