DR650 Carb Swap (pt 1) - Mikuni TM40 Rebuild

My DR650 has a self-inflicted fuel starvation issue at highway speeds. The used OEM carbs are selling for ridiculous prices, so I bought a used Mikuni HS40 (TM40) flat slide carb off a Harley for a reasonable price. It needed a good cleaning, rebuild, and rejetting before I could install it on the DR650.
Ultrasonic cleaner 22L 🔗 amzn.to/3iVaBeH
Krud Kutter cleaning solution (safe for aluminum) 🔗 amzn.to/36PCMJh
Mikuni TM40-6/HS40 rebuild kit 🔗 www.ebay.com/itm/Genuine-Miku...
Accel pump nozzle (size 35) : amzn.to/3KzsxbC
Accel pump nozzle ( Size 40 ) : amzn.to/3R6gsNp
Accel pump nozzle ( Size 45 ) : amzn.to/3pZmDqF
Accel pump nozzle ( Size 55 ) : amzn.to/3CFvVQm
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Other videos in this series:
Part 2 - Making throat adapters for the TM40: • DR650 Carb Swap (pt 2)...
Part 3 - Installing TM40 and shorten cables: • DR650 Carb Swap (pt. 3...
Part 4 - Tuning the TM40: .....coming soon
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[@coryjs9646]

Huge thank you for this video. I got a DR650 with that carb but it leaks when parked. Ive been looking at which orings I need and this is helpful.

[@jhackett9482]

You need a set of JIS screwdrivers. They are made for Japanese screws and wont strip like American drivers. I bought set and love them.

[@DustinRogersinMO]

I really do. I’ve been meaning to order a set for a long time.

[@Pebblepaul]

This is a very helpful video thank you for putting it together, however it would’ve been so much more effective if you had not sped up the disassembly and reassembly steps.

[@ricardojavierrivera4353]

Hi Dustin
I’m working on the same carb to use on my Xr650L is most the same settings just looking the part number for the accelerator pump nuzzle thanks for the info
Great videos

[@DustinRogersinMO]

Thanks. I put some links to the common sizes of accelerator pump nozzles in the video description.

[@tonyklementsen1778]

Hi. i notised on the fuelskrew that you took the oring on before the washer. I think you have to swap them so the oring is the last you put on. thanks for your video.

[@patring620]

I was going to say the same thing. The original is as you describe - spring, washer, o-ring.

[@lucasazeredo1]

another JIS set of screws bites the dust :(

[@Pebblepaul]

I cannot figure out where this Excelerator nozzle plug goes? The current one did not tm 40 did not have one and I have no idea how this fits?

[@jackfrost7400]

Is their a throttle stop screw? On top of the carb to hold the throttle open for higher idle like the original carburetor?

[@DustinRogersinMO]

@@jackfrost7400 there is a screw that will keep the slide open to a set position. It’s the big knob on the side of the carb

[@jackfrost7400]

@@DustinRogersinMO thanks I just started it and u are correct awesome thanks for the quick response 👍