Suzuki DR-Z400S 2001 Service Manual page 118

Remove the following parts.
1 Valve seat 5 Needle jet
2 Main jet 6 Starter jet
3 Pilot jet 7 Pilot air jet
4 Pilot screw
NOTE:
Before removing the pilot screw 4 , its setting must be deter-
mined. Slowly turn the pilot screw clockwise and count the num-
ber of turns until it is lightly seated. Make a note of how many
turns were made.
When reassembling the pilot screw, you will want to set the pilot
screw to its original position.
Do not use wire to clean the passageways, valve seat,
and jets. Use compressed air only.
PILOT SCREW REMOVAL (FOR E-03, 28, 33)
Because harsh cleaning solvents can damage the O-ring seals
in the pilot system, the pilot system components should be re-
moved before cleaning.
Use a 1/8" size drill bit with a drill-stop to remove the pilot
screw plug. Set the drill-stop 6 mm from the end of the bit to
prevent drilling into the pilot screw. Carefully drill through the
plug.
Thread a self-tapping sheet metal screw into the plug. Pull on
the screw head with pliers to remove the plug. Carefully clean
any metal shavings from the area.
Slowly turn the pilot screw clockwise and count the number of
turns until the screw is lightly seated. Make a note of how
many turns were made so the screw can be reset correctly
after cleaning.
Remove the pilot screw along with the spring, washer, and O-
ring.
After cleaning, install the pilot screw to the original setting by
turning the screw in until it lightly seats, and then backing it
out the same number of turns counted during disassembly.
Install a new plug by tapping it into place with a punch.
1 Drill-stop
2 Plug
3 Pilot screw
4 Carburetor body
FUEL AND LUBRICATION SYSTEM
2
1
5
3
7
4-9
6
4