1982-1985 Suzuki SJ410 New Carburetor Repair Kit

Fit In Five Steps

How to replace a  Suzuki SJ410 New Carburetor?

1.Secure the Vehicle

Open the hood and remove the air cleaner assembly to gain full access to the carburetor. Apply the parking brake and start the engine. Inspect for fuel leaks around the seals of the carburetor. Disconnect the battery and fuel lines at the carburetor.

2.Locate the Carburetor

Locate the carburetor assembly on the engine mount. Disconnect throttle linkage (If it is an automatic). With the engine still running at idle, adjust the air/fuel mixture screws. If the idle does not change, the carburetor needs to be replaced. Shut the engine off and inspect the carburetor throttle bore. Carbon in the throttle bore indicates a rich fuel condition typically caused by internal carburetor damage. Label and disconnect the rubber vacuum hoses from the carburetor.

3.Remove the Old Carburetor

Pinch fuel lines with specific fuel line crimper tools and remove fuel lines from the carburetor. Disconnect the throttle linkage from the carburetor. Before loosening mounting nuts from the intake manifold studs, be sure that all lines are disconnected and labeled. Loosen the nuts from the intake manifold stud bolts and remove the old carburetor.

4.Replace the New Carburetor

Compare the old carburetor to the new carburetor to verify that you have the correct part. Remove the gasket between the carburetor and intake manifold and replace it with a new gasket. Carefully set the new carburetor onto the new manifold gasket.

5.Rearrange all Removal Parts and Test Drive

Install the mounting nuts and tighten them securely. Reconnect the throttle linkage and all the lines to the new carburetor as indicated by the numbered tape on the old carburetor. For a quick starting tip, you can close the air/fuel mixture screws all the way, and then open them 1 full turn each. We strongly recommend having the carburetor adjusted by a certified technician.