TS 185 ER

[Dungar Pilot]

Hi All,

Hopefully someone on here can help as I am working on a recently acquired bike, 7500 km on clock, stock standard, unmolested and been in storage for a long time. I have it starting and idling beautifully and it pulls OK in bottom end then runs Rich? The carby was a bit gummed up especially around emulsion tube. Attached is a photo of slide assembly roughly in the order it came apart.
1 Is this the right order?
2 Why is there a spring on the Needle?
3 Can someone recommend the correct circlip position?
Trials is my thing and I don't remember ever seeing a spring on a needle Before!

Thanks in advance

Greg
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[cyclegod]

It's a bad design that I really hate but there is an odd quirk, the retaining plate (which can go either way up) that goes over the top of the needle to keep the cable in place has a raised piece on it that makes the needle stick out at a slight angle instead of straight up and down.
I sanded that off as I felt it made the needle rub on the needle jet and wear both enough to alter the jetting in the middle range. A new jetting kit with needle on the middle clip and my mod totally transformed it.
Another ER quirk is that the exhausts leak badly at the cylinder due to a weak design and that can affect performance a lot. I cut a new steel plate from 12mm sheet and welded it onto the pipe (like the TS100/125ER) with all new gaskets and spring and it never leaked again.

[pokey]

http://suzukits.informe.com/forum/viewtopic.php?f=7&t=3214&p=28278#p28278

[Dungar Pilot]

Hi All,

Thanks for the replies,

 cyclegod, you have me rethinking my Avatar! I have done your mod and I can now fit the slide with the air cleaner still attached, much Better! The Centre position was better and the second leanest setting was better again but still not right so I removed the rubber snorkel thing and better again but still not right. Now I am pretty sure that the air box that came separate with the bike is not right. There was a very faint 100 in white paint pen so I am thinking TS 100? Are they the same air box with reduced openings? The mounts on top were different and spigot for genuine TS185 ER rubber boot was too small, being a Sheet metal worker was an easy fix. But I still think opening for air into box is too Small? Anyone have a photo/Diagram? Gave it a good run and worked it up hill, no one could have followed because of BLUE smoke but this did not change power charactistics!

pokey, remember the TS 90? Your link was very helpful re assembly Order!