My 03 drz400e with FCR 39 carb is giving me some difficulty. It contains stock jets (165 starter, 145 pilot) except for DJ stage 2 kit 136 main, stock needle 4 from top, fuel screw about 2-1/4 turns and the UNI air filter. I had the stock pipe on and it was fine with some minor bog at wot. I had wired the acc pump according to eddie's mod which eased the bog, but didnt make it disappear. With that said, I have never been real happy with the surge/ lug at higher RPM range especially when trying to ride highway for any length of time. Anyway, I recently picked up a used full yoshi rs3 pipe and decided to address all carb issues as I figured it would need a rejet anyway.
SO, after some creative language getting the yoshi header and midpipe to line up, I decided to ride and see what happened. Results were alot louder as expected and worse surging issue while cruising especially around 5000 rpm and higher. At lower rpm and as long as accelerating all is well. Trail riding wasnt an issue, just twitchy at higher rpm cruising.
I removed and cleaned carb, broke out the dj kit remnants and instructions and swapped the dj kit main jet for the 140 and moved the clip to position 5 as instructed. Seems a little better but not much. I checked the float height and is within spec: 9MM. Of note, the spark plug was pretty greasy and black (rich) so I replaced with new at this time.
I decided to remove the ACC pump and found the diaphragm shot to heck, so a new rebuild for that is in order. This might effect the bog, but I am not sure that recent aggressive carb cleaner application did not just damage it. Anyone understand this carb enough to know where else to go with this?
Could the diaphragm damage cause the surge I am experiencing? I suppose there could have been trash from the diaphragm floating around in the circuits causing problems somewhere, but all jets and crud build up seemed minimal, and all circuits seemed to pass air fine.
Anyway, I am ordering parts ( acc pump diaphragm and orings, needle valve carb basic kit) and thought I would post up before jic anyone recommends other parts I havent considered. I have gone down most rabbit holes on thumper and just trying to fully understand how this thing works.
All help appreciated, thanks.