"Life seems so much simpiler when you're fixing things. I'm good at fixing things." -- Anakin Skywalker
While troubleshooting a performance problem on my 1999 Suzuki Savage, I decided to take apart and clean the carburetor. The problem turned out to be elsewhere, but while I had everything apart, I decided to take some pictures for future reference.
The numbers you see on the photographs correspond (I hope) to the drawing numbers on the microfiche that you can find at Temecula Motor Sports or Ron Ayers. I gather these are official diagrams distributed by Suzuki, as they appear to be identical.
Disclaimers: I may have mis-identified some of the parts. (If you notice any goofs, email savage (at) thinkythings (dot) org.) Also, you probably shouldn't try this yourself unless you're sure you know what you're doing. Carburetors are complicated and contain sensitive parts. It's easy to break something. If you have problems, you should probably consult a motorcycle mechanic. I almost certainly can't help you, and I'm providing these pictures only to document what I did, not as a guide for what you should do.
Part numbers (from the aforementioned diagram):
1 .SPRING 2 .DIAPHRAGM ASSY 3 .PLATE 4 .SCREW 5 .LOCK WASHER 6 .RING 7 E RING 8 .WASHER 9 .SPRING 10 NEEDLE, JET (5C39) 11 .JET, NEEDLE (X-7M) 12 .JET, PILOT AIR (45) 13 COVER 14 CLAMP (L:95) 15 SCREW, CLAMP 16 .JET, MAIN (145) 17-1 .WASHER 17-2 .WASHER 18 .JET, PILOT (52.5) 19 .VALVE ASSY, NEEDLE 20 .FILTER 21 .O RING 22 .PLATE 23 .SCREW 24 FLOAT 25 .PIN, FLOAT 26 .GASKET 27 SCREW 28 .SCREW, DRAIN 29 .PLUNGER ASSY 30 .COVER 31-1 .SPRING 31-2 .SPRING 32 .DIAPHRAGM ASSY 33 SCREW 34-1 .ADJUSTER 34-2 .ADJUSTER 35 .SPRING 36 .BRACKET 37 SCREW, CLAMP 38 .HOSE ASSY 39 HOSE (L:600->200) 40 .JET, PILOT AIR NO.2 (230) 41 .SCREW, PILOT (1,1/8) 42 .SPRING 43 .WASHER 44 .O RING 45 .PLUG
The carburetor is located between the air intake and the engine. It's the thing with the most hoses connected to it. Some of the carb is hidden by the gas tank.
Accessing the carburetor involves taking off the seat, then disconnecting all the cables and hoses. With persistence, it is possible to remove the carb without taking off the fuel tank; however, I found it was necessary to remove the fuel valve in order to be able to lift the tank a bit. This implies draining the tank by setting the value to "prime" and putting the fuel line into a suitable container.
It takes a lot of twisting and pulling to get the carb out of its position. Once it is out, it will continue to dribble gasoline.