That's it I guess. My 1994 DR650 SER rebuild project is complete. I've fixed the return pipe O-ring leak. The O-ring was twisted like the waste band of a schoolgirls knickers. They say put it in with GREASE. They know stuff. Got to ease that thing in then work it so it settles without winding it into a pretzel.
The carb is DONE. It's hard to find any fault. It idles, it creeps, it pulls, it comes off full throttle back to idle WITHOUT STALLING , geeze guys, this has been a bloody test of my patience !
I can say this. The BST40 works when it's new. It ages fast. It dies even quicker than your piston/bore clearance when some fukwit lets the air cleaner rot and fall apart. If you make it NEW again, it works and works well. Maybe not as good as an alternative. It has a bad rap the BST , but it's the same carb on many other bikes.
It would probably benefit from a 1.2 pilot air jet to replace the 1.3 , IMHO , I read that someplace, it makes sense to me now.
Given what folks say about other carbs, if I were to do this dance again, I'd go aftermarket. However, it did only cost about R1700 all-in to replace all the wear parts, and thanks to Motolab for that, or it would be IMPOSSIBLE with Suzuki, who don't have those plastic parts to sell !
Anyway, my carb is set now to wear IN , as opposed to wear OUT. As the needle/nozzle gets worn, it will get better instead of worse, well, at least initially !
The only item left on my To-Do list for this bike is to replace the front disk which is at minimum thickness of 4.0mm , I'll take my time with that.
Maybe some fork vroeteling but no rush either.
So I have a near-stock 1994DR painted with Velvaglo Dirty Khaki , but it runs sweeeeetly , FEELS like a relatively new ride, goes like snot compared to most 650 thumpers, including my own Stage 1 '08 DR , and my all-in wallet I think is R37 000 for a bike with... mmmmm , about another 75 000km live left in it as it stands.
When I think I sold my KTM640 for R58k , I am very, very happy with my Old School Downgrade !!!!

Keep the faith gents, this bike is worth the work and the fuss.
And as I sit here the renewal notice arrives ! Yes, one full year it took.
Do It !!!