SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> New pilot jet, idles fine but dies with throttle
/cgi-bin/YaBB.pl?num=1767424800

Message started by Riddmkidd on 01/02/26 at 23:20:00

Title: New pilot jet, idles fine but dies with throttle
Post by Riddmkidd on 01/02/26 at 23:20:00

Took my carb apart today...most of the way. It looks pretty clean in there already which was nice. I've been having hesitation when opening the throttle so I was hoping to fix it today. I have an all balls rebuild kit and decided to install the new pilot jet and then button everything back up.

Now she idles much better than before and started right up kncd the float bowl was filled. I have the raptor peacock BTW. As soon as I Crack the throttle she bogs down and dies. Research is saying I have a clogged pilot jet or possible air leak.

The hole in the new jet was definitely more clear than the original. I'm soaking the original in carb cleaner. Is the increased fuel flow of the new jet the culprit? What have I missed?

Title: Re: New pilot jet, idles fine but dies with throt
Post by Riddmkidd on 01/03/26 at 01:54:53

here's a couple photos of what my carb looks like. added the text to remind myself what goes where. the pilot jet was stuck in there and took some fiddlng with to get it out. installed everything back together with all the here fully seated I think.

https://imgur.com/gallery/qtx5Dge

Title: Re: New pilot jet, idles fine but dies with throt
Post by LANCER on 01/03/26 at 02:17:24

What is the number on the pilot jet you installed ?
And what is the number on the pilot jet you removed ?

Did you change anything else ?

Title: Re: New pilot jet, idles fine but dies with throt
Post by Riddmkidd on 01/03/26 at 12:20:31

I'll check the numbers when I take it apart. it's the only thing I changed unless I forgot a step during reassembly

Title: Re: New pilot jet, idles fine but dies with throt
Post by Riddmkidd on 01/03/26 at 14:34:01

sigh, I had the petcocks confused. my other bike has RES at the 9 o'clock position which is OFF on this bike. know she revs just fine. definitely a facepalm moment....I hope this brings a chuckle to all who read this.

btw my other bike is a 1965 Honda cb77 super hawk. what a different ride...

Title: Re: New pilot jet, idles fine but dies with throt
Post by LANCER on 01/04/26 at 05:55:24

Looking at the photos you provided did not help, and you didn’t provide the numbers on the pilot jet and main jet.
Also, you mentioned that the pilot jet was hard to remove, which is from collected debris in the carburetor. You can be sure that if it’s around the pilot jet, it is elsewhere in the carburetor as well. That would likely be in the tiny passageways in the carburetor body. There are several tiny passageways in the carb body, and they MUST be clear for the carb to function properly. Those passageways can be cleared with: aerosol carb cleaner, compresses air, and a carb cleaning tool (the tool has about a dozen tiny wires to clear the passageways; it’s similar to the tool used to clean the jet nozzles of a gas welding/cutting rig).
Once we have the pilot & main jet numbers, so we can be sure of what you are dealing with, you start a complete cleaning of passageways.
Start with the aerosol carb cleaner, and be careful because when it comes out the other end of a passageway it can spray you in the face. Then, if needed, use compressed air, the carb tool (or a piece of a tiny electrical wire).
When you have the correct jets, and clear passage ways, the carb will function properly. Once this is done, if the carb is still not functioning properly then you can begin to isolate other parts that may be a problem.

Of course, check for air leaks between carb and head, and between head and exhaust, in case these may affect running.

Title: Re: New pilot jet, idles fine but dies with throt
Post by Ruttly on 01/04/26 at 08:37:00

If float bowl is corroded & crusted up I’ve used battery terminal cleaning spray or paint removing spray to remove buildup. Both are bad for skin & eyes , use caution ! So don’t spray it in the bowl ! Spray on something flat and use a brush to apply. May need more than one application. I have some carbs over 50 years old. Completely cover corrosion let sit for a while/overnight , after cleaning soak in fresh oil , if not it will begin to corrode almost immediately !

Title: Re: New pilot jet, idles fine but dies with throt
Post by Riddmkidd on 01/05/26 at 17:08:56

(Looking at the photos you provided did not help, and you didn’t provide the numbers on the pilot jet and main jet.)

52.5 and 145 are my jet sizes.

(Also, you mentioned that the pilot jet was hard to remove, which is from collected debris in the carburetor. You can be sure that if it’s around the pilot jet, it is elsewhere in the carburetor as well. That would likely be in the tiny passageways in the carburetor body. There are several tiny passageways in the carb body, and they MUST be clear for the carb to function properly. Those passageways can be cleared with: aerosol carb cleaner, compresses air, and a carb cleaning tool (the tool has about a dozen tiny wires to clear the passageways; it’s similar to the tool used to clean the jet nozzles of a gas welding/cutting rig).
Once we have the pilot & main jet numbers, so we can be sure of what you are dealing with, you start a complete cleaning of passageways.
Start with the aerosol carb cleaner, and be careful because when it comes out the other end of a passageway it can spray you in the face. Then, if needed, use compressed air, the carb tool (or a piece of a tiny electrical wire).
When you have the correct jets, and clear passage ways, the carb will function properly. Once this is done, if the carb is still not functioning properly then you can begin to isolate other parts that may be a problem.)

the carb is functioning and the bike is running again. I replaced[original sock pilot jet with the new one. I do plan to do a full clean of the carb in the future.

(Of course, check for air leaks between carb and head, and between head and exhaust, in case these may affect running. )

no leaks so far thank goodness.

Title: Re: New pilot jet, idles fine but dies with throt
Post by LANCER on 01/06/26 at 03:45:08

What year is your bike ?
With a 52.5 pilot and a 145 main jet, it makes me think it’s an older model from 86–93. That pilot jet is a good size, but I much prefer a 150 or 152.5 main jet, you get better performance at higher speeds on the highway with those.