How To Rebuild A DRZ400S Carburetor

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[@curtisdavis4451]

2nd comment....my bike has never ran better...I can't remember it ever starting so easily, no choke, touch the button, boom, purrs like a kitten. I did the carb sonication in a ziploc bag (my cleaner is much smaller)VERY happy, thanks again for all the detailed steps.

[@motomecha530]

Awesome! The cleaner the better!

[@MrDrifter101]

Most educational carb video I’ve ever watched! Thanks for being calm and thorough!! 10/10

[@motomecha530]

Thanks! I'm glad you liked it!

[@AxisDSTC]

Second time opening the DRZ carb now. This time its a rebuild kit and this will be helpful. Thank you!

[@charlieruss2128]

Thanks for the video. Helped me out a lot today when I was rebuilding my carb!

[@gibidygubidy]

Excellent. Thanks to this video I've solved a carb problem that's been driving me mad. I've had the carb out of my drz countless times now I could now do it with my eyes closed but until I saw the compressed air to check correct slide function I didn't notice mine wasn't working properly. Compressed air as described indicated something wrong ...I had the diaphram on inside out or upside down.. switched it over and bike is now running like a champ! Thanks for this ..

[@motomecha530]

Glad it helped!

[@curtisdavis4451]

Just cleaned my 2006 drz carb, it was definitely needed. Perfect description, step by step. My only hiccup was at the end of ultrasonic cleaning, I lift the carb and a tiny silver bearing falls out, hits the floor, gone! Took me an hour to find it. It was the ball bearing for the choke position slide. Lesson learned, have a tray and rag under the carb when removing from the ultrasonic cleaning 👍

[@motomecha530]

I lost it too actually and found it, was that tiny spring still in there?

[@curtisdavis4451]

@@motomecha530 yep, spring was there. I had to stare at the carb blowout pics for a while till I finally figured out where it came from.

[@TOM-o2b2c]

Great video. One suggestion to mention the choke spring and ball bearing when coming apart. I had no idea about it and it is gone.

[@motomecha530]

Yeah, I'll admit I forgot about mentioning that. I did the same, found the ball bearing and luckily the spring was still in there thank God!

[@ericcandel6086]

Hello, thanks a lot for this vidéo , i have to rebuild my carburator and with this tuto i think i can do myself. 👍

[@roninmotors7466]

Do you rebuild these for customers via mail?

[@jayminasi6073]

they are NOT phillips screws, they are Japanese Industrial Standard and it makes a difference to use the right screwdriver.

[@pk8363]

👍 definitely worth a mention to avoid rounded off JIS parts don't use a Phillips bit.

[@motomecha530]

Ya, I need a set!

[@brandnamejessx5361]

The larger diameter o ring that is thinner, what does it go to? I notice you didn't use it. Is it for a different setup? Perhaps the o ring it replaced wasn't bad and so you just didn't put the new one in? I can't find any information from they who sell the rebuild kits, as to what the parts are to where they go. Awesome video! Very helpful, Thank you so much.

[@motomecha530]

uhhm, yea could have been for a different model. it's more cost effective for the manufacturer to just put together a kit that works for several different models.

[@z33tanner]

Thank you for a detailed walk-through. Rebuilt carb with mikuni kit, 3x3 mod, and JD jetting kit 160main blue needle on clip 4. In CA at sealevel. Pulls so much harder over entire rpm range, plus more induction noise im so stoked!!!

[@950boy2]

25 pilot? is that with an aftermarket pipe too?

[@motomecha530]

Yeah what a difference huh!?!?

[@JesusChrist_IsTruth-LoveForALL]

How many turns out on the fuel screw?

[@kpunk4247]

That made my head explode 🤯 My Drz400s 2007 cuts out at full throttle.. Has been the same for 2 years... Never done this before.. No idea what to do & no decent mechanics in cambodia 😎

[@motomecha530]

Give it a shot! Plenty of information out there the help you out!

[@chonjacki]

Great video! This will be really helpful to use as a guide. What are those long nose pliers you're using?

[@wojciechogloza6428]

I've seen people "clean" a carb. Never like this. Super cool thank you.

[@motomecha530]

Glad you liked it! Clean is key!

[@edaiken1010]

Very well done. I didn't know not to remove the throttle position sensor. Hope I didn't cause a problem with re-assembly. I was surprised that you would put the electrical parts in your ultrasonic cleaner. I wish I had that cleaner. I just spray everything with carb cleaner.

[@kraigtomlinson2201]

What are the internal dimensions and make/model of the ultrasonic cleaner that you're using? How many transducers are used in the tank? Were it to fail, would you buy another identical unit? I'm looking for a good, reliable utrasonic cleaner that doesn't break the bank... Also, what cleaning solution are you using and the dilution ratio (to water - I assume...)? And lastly, are there any ways to keep this shellac-like buildup from forming or at least slow the buildup? Run non-ethanol (pure) gasoline only? Are there any effective fuel additives?

[@motomecha530]

I'll check on the Ultra sonic cleaner. I believe it's from K&L Supply tho... Not sure the details. But one like this is about 2K The cleaning solution is also from K&L. I've had very good luck using a combination of Carpet cleaner, simple green and power purple. Ideally using fuels without ethanol but hard to find. Fort Nine has a pretty good video on comparing a few different fuel stabilizers.

[@kraigtomlinson2201]

@@motomecha530 So, fuel stabilizers minimize or prevent the buildup? Would you recommend always using fuel stabilzers year round on bikes w/carbs, if so? Will 100% gasoline keep carbs clean(er) if you occasionally use ethanol gas?

[@bro_mayo5413]

Make sure the fuel screw plug is the right plug before you drill it lol. I may or may not have drilled the one below it and now I am applying epoxy...

[@motomecha530]

LOL easy mistake

[@bro_mayo5413]

@@motomecha530 Ran great after epoxying the plug. I guess I had either removed the fuel screw plug at some point or my bike didn't come with it so I figured the one below was it lol.

[@caymccarp34]

Great video, thanks for taking the time. Any Idea what size ball bearing is used for the choke. My decide to roll away some where.

[@motomecha530]

Oh god, have no idea. I though I lost mine too but it was in there after all, double check it’s not still in there. Good luck!

[@caymccarp34]

@@motomecha530 Partzilla has the spring but no bearing. I'm gonna just try different size ball bearings. I'm sure something is better than nothing. Might even measure the dia. Of the spring and start looking from there. Thanks for the reply.

[@steeledowning]

Do you not need to replace the fuel mixer cover that you drilled out? Neither kit I’ve bought came with a replacement.

[@motomecha530]

Nope, leave it open for tuning purposes.

[@awboaz]

Great video but beyond my ability is there a place I can mail my carburetors to b rebuilt

[@pantera31169311]

Do you have a motorcycle repair shop? We're are you located and how can I get in touch with you? Thanks

[@MrDelgadoHD]

What would you recommend using if you don't have access to an ultrasonic cleaner? Love the video by the way, just ordered my Moose carb rebuild kit for my 06 KFX400!

[@motomecha530]

Soak the carb in carburetor cleaner overnight and make sure you wash it well with hot water and blow out every passage with compressed air

[@shythead17x41]

Best video I’ve ever seen! Perfect pace, very informative!

[@motomecha530]

Thanks!

[@Apollohistory11]

Great job! - valuable step by step guide to doing the job!

[@motomecha530]

Thanks!

[@macking4942]

Hey Mike. What were the small O-ring gaskets left over? We took our bowl off, all the jets out and diafram needle out. Left float and all intact. When we went to put it back together, we were left with a small o ring?? We took it back apart and the main jet holder has its o-ring. So we are not sure where this one would have even come from????

[@macking4942]

i found it! it was the diaphragm top o-ring. hopfully the rebuild kits from moose comes with another one. Its not in good shape.

[@elijahman5769]

Thanks for the update​@@macking4942

[@AmjadKhan-qy6om]

Thanks for this. Really a great help. You did it so professionally.

[@motomecha530]

Thank you!

[@bigleftlcn]

Tha k you so much for this video, I wish you had the tuning video up after installing the carb, im about to embark on this whole process. Sticking with stock everything any tips on tuning after setting to 2 1/4? For idiots lol.....ty

[@motomecha530]

It can be very complicated. I unscrew the mixture screw to listen for idle raising, then when the idle starts going back down and screw it back in a half turn. Also if it has a lean popping sound on deceleration then it's too lean and needs to be backed out, or a larger pilot jet.

[@stevehardeman7209]

Just received an 01 drz400e ,is this same carb ,and have you ever had luck with mechanic in a bottle for carb cleans ?

[@motomecha530]

Only if the carb JUST started clogging up. but 99% of the time you need to take em apart and do a deep clean.

[@giovannimitreski8478]

What do u use in your cleaner

[@jamesrowlinson8763]

Hey mate, Thanks for the video I studied it intently I've just had a carby inspection day due to fuel leaking out of the overflow. Replaced the gasket round the bowl, the needle valve and its seat. On connecting it up again fuel was pouring out of both the overflow and the vent tube at the top... Any ideas on how to fix? Also nervous as given the vent tube is above the butterfly valve I'm worried its poured into the engine. Thanks, much appreciated in advance

[@motomecha530]

Usually that means that the needle valve is not seating. Sometimes I tap the side of a carb to try and knock that valve into position. Good luck!

[@gibidygubidy]

Man.... I needed this. Thank you!

[@motomecha530]

Any time!

[@markofiorovic1573]

hi mate, is there any frequence for cleaning, once every two years or just when is cloged?

[@motomecha530]

Ya pretty much when it’s clogged. Use fuel stabilizer when not running the bike for extended periods of time.

[@markofiorovic1573]

@@motomecha530 thanks mate

[@pk8363]

Very useful video. Thank you for taking the time to do it.

[@motomecha530]

You're welcome!

[@elementboi151]

What solvent/degreaser are you running in your ultrasonic cleaner?

[@motomecha530]

K&L Chem-Crest

[@Motovibes91]

Hi my 2006 Suzuki DRZ400SM only starts with full choke on (even in hot weather) and needs a minute to idle before I can turn the choke off, otherwise it will stall. Maybe you know a solution?

[@motomecha530]

That's normal for a lot of carbureted bikes. Is it due for a tune up? did it sit for while (over a month or two even) with gas in it? Are the valve clearances in need of checking? Could be several different causes.

[@ramiroherrejon4132]

Thanks for the great video, what is the purpose of the little plastic you forgot,? my carburetor doesn't have, some one forgot to put it in.

[@motomecha530]

Uhhm I think maybe to prevent the pilot jet from falling completely out... I'm not 100% sure

[@cartaun5276]

Here's a solid like my friend. Good, clean work

[@motomecha530]

Thanks!

[@steeledowning]

Also my dumb ass busted two tabs off the rod guide in the diaphragm. I can’t seem to find a replacement without buying a whole new carb. Any suggestions? Think I could try to jb weld it?😔

[@motomecha530]

Hmm not sure what you're referring to.

[@ope.-817]

​@@motomecha530I think he meant the plastic in the diaphragm that seats the plastic piece holding the needle

[@OliverMunroe]

Awesome video Mike! i did the exact same thing - forgot the little plastic piece and had to take the float bowl back off >D

[@motomecha530]

Thanks! Hoped you learned something. I’ve made every mistake so I get it!

[@kevinwestphal380]

Thank you for this awesome tutorial!

[@motomecha530]

My pleasure! Hope it helped!

[@GoGoober]

Niiccee Mike!! Dude I've never seen inside of a DRZ carb this is awesome👌

[@motomecha530]

They are very complicated and fascinating huh? And a HUGE pain to keep running well.

[@alanone69]

I just need to bring my bikes to your shop, lol.

[@motomecha530]

Ya, hit me up!

[@SyntheticWords]

Thanks for the video man!

[@motomecha530]

Thanks for watching!

[@patrickwardle3043]

Very helpful

[@wanagoboom7209]

My man! Need to do this but on a 2002 R6. Its like you are reading my to do list.😅

[@motomecha530]

Yeah, those can be temperamental. Just make sure they are clean AF and synched up!

[@wanagoboom7209]

@@motomecha530 any chance of carb synching video anytime soon?

[@peterim1791]

Thanks learned a lot

[@motomecha530]

Sweet! Glad you liked it!

[@oscarbear7498]

I tried this and I stripped the screw :( I tossed the whole thing in the trash and got a new carb.

[@rw1567]

You warned me about the small ball bearing for the choke too late. She gone

[@fpso206]

Not going to check float level adjustment? ALWAYS check / adjust float level!

[@motomecha530]

Ya I usually do. Some carbs are non adjustable.

[@saulparra4615]

10 out of 10 perfect.....😎

[@motomecha530]

Thanks!

[@rsilvers129]

I replaced the four bowl screws with Torx.

[@motomecha530]

Smart!

[@pk8363]

The float bowl screw that also holds the metal bracket for the breather pipe is longer than the other 3.

[@ivoperic3992]

Best of all, I like doughnuts. Rest is too complicated.

[@motomecha530]

LOL! Yes they are!

[@6mer1man9]

I have one of these :)

[@motomecha530]

Get it running!

[@pucknhusker9426]

Thanks mate very helpful.

[@motomecha530]

My pleasure! Hope it helped!

[@kenchristopher5479]

I would like to see a dino before and after.

[@KindergentlerMr.Softbelly]

Super job. I’m getting ready to rebuild one and this is a great help

[@motomecha530]

Great to hear!