I recently had a dynojet kit installed on my 93 dr650rs....... i left the side of the airbox and fired her up, with a new air filter and 160 main jet she sounded MAD, so i re-fitted the airbox and it cut out immediatley, and now she wont start..... no spark, and theres fuel getting in........ what have i dun? any answers appreciated thanks

Richard, I would suggest you go with a stage 3 jet kit for improved air flow. Ebay has them for a great deal. I'll post a link. Good luck. ^^
Dynojet Stage 3 Jet Kit For Suzuki GS650 GS 650 1981 1982

Try covering up the holes in the airbox (where it has been cut away) with tape. If it runs better, you know the jet size is too small. Sometimes the jet kits don't go big enough for a modified airbox.

take in mind the setting that they give you is a base setting somewhere to start to get you in the ball park. your rear cylinder going have larger jets then you front due to heat. and where you live is going to affect the jetting as will. this is how you fix your problem. first what is everything set at i.e. main and pilot jet in front carb, needle clip setting (from bottom) and air/fuel. write this down send it to me. next what color is the front plug, what color is the rear plug. what you want is nice coffee cream tan.
Now you can't base dynojet jet sizes ex. o.e.m main jet 150 you could have a dynojet main of the same size but the number will WAY different. I have asked them a dozen times if once why they don't was oem sizing to make things easier on us and all the say "our jets, our sizing" write this info down we will need it later. Get it back to me and we will jet this thing right
fix it right, ride it fast
M.Woodring

When too much fuel is being supplied to the carburetors the engine is flooded. When you remove the spark plugs it allows the fuel to dissipate enough to allow the engine to run again. Drilling out the jets is not an accurate/preferred method for changing the jet size. Most of the time the jets end up being drilled too big. You can save money by just buying main jets. A jet kit usually will come with the slide needles made with a different taper from the stock needles. You may need to break down and buy a jet kit or a least replace the main jets with accurately sized main jets (not drilled out jets). In other words your main jets are just too big.

HI A DYNOJET KIT INCLUDES MORE THAN JUST MAIN JETS, AIR CORRECTORS, SLIDE NEEDLES, AND IN SOME CASES NEW SLIDE SPRINGS ARE INCLUDED, SLIDE LIFT HOLES ARE ALSO DRILLED OUT TO GIVE QUICKER THROTTLE RESPONSE, AS DAFT AS IT MAY SEEM YOU NEW MAIN JETS IN MOST CASES WILL BE SMALLER THAN THE ORIGINAL JETS, IF YOU ARE THINKING YOUR BIKE HAS BEEN DYNOJETED BUT ARE NOT SURE CONTACK DYNOJET UK FOR HELP, HOPE THIS IS OF USE FOR YOU,
http://www.dynojet.co.uk/jetkits/index.htm

Intended for motorcycles with a stock engine using the stock airbox, air filter and stock pipe. Stage 1 kits are fully adjustable to allow the use of a well designed aftermarket pipes and stock replacement air filters like K&N. Stage 1 kits are designed to improve throttle response and driveability and in most cases power increases of approximately 5% throughout the entire power range can be achieved.


STAGE ONE INSTRUCTIONS
1. Remove the vacuum slide from the carbs. Remove the stock needles & spacers, noting the order of
assembly. Locate the slide lift holes (Fig. A), with the slide drill DD# 14 supplied, enlarge your slide lift
holes. The picture may not show your slide exactly, enlarge your slide lift hole or holes depending on your
model. Do not drill any new lift holes. Do not drill the needle hole.
2. Install Dynojet needles on groove #4, using all stock spacers. Install the Dynojet washers (2 per
needle) above the E-clip.
3. Remove the stock main jets and replace with the Dynojet main jets provided. If you are running with
stock exhaust, use the DJ110 main jets. With an aftermarket header or slip-on with high flowing baffles,
use the DJ116 main jets. Be sure that the jets you are changing are the main jets.
4. Locate the fuel mixture plug (Fig. B), if you see a screw head, proceed to adjusting procedure. With the
DD #5/32 drill bit provided, carefully drill thru the plugs. Note: the mixture screw is directly underneath this
plug, be ready to pull back on the drill the instant you break thru. Use screw provided to secure and
remove the plug. Carefully turn mixture screws clockwise until they seat, turn out 3 turns.


For further info on this, visit: http://www.dynojet.com/jetkits/motorcycle/honda.aspx

You can find the manual for the model you are searching for. Follow the 1st column "CC" to find 650cc models and you can find your specific model after that.

Thanks for asking.
Regards,
Arvind S Iyer

If there is NO spark at all, it is definately electrical. Any chance when fiddling with the airbox cover that the sidestand switch wiring was disconnected? This acts like a kill switch when stand is lowered. If you have spark you may have to live with leaving the cover off. My '90 DR650RS starts sweetly first kick with the seat off, but struggles when seat is on. When it is hot it will not start with seat on...so I drilled several 1/2" holes in the top of the airbox and problem was solved. I run a CZR muffler with stock carby/#160 jet.
Cheers.

No it won't run very good, your model has CV carbs, they like that air box behind them, you will need to go to Dynojet and get a jet kit, that will likely fix our problem.

Dynojet

its likley to be running a bit to week,, try opening up the fule mix screw just a bit to let in more fule

If you are not running an open or free flowing exhaust go back to the stock size jets but use the DynoJet parts instead of the stock.
DJ jets tend to run bigger than oem jets