Just wanted to share with you my experience this weekend in rebuilding the OEM carb on my 87 Samurai. The instructions and schematics indicate for the Pump Discharge Check you install a ball, weight, spring and weight, and set the float level to 8mm with the bowl cover inverted. This did not solve my carb issue but made it worse. In my tear down I thought that I lost the spring and one weight. So I used a spare that I had. The float level was at 16mm so I reset to 8mm. Fired it up and it ran crappy. Eventually, after many adjustments (I am now a pro at removing the float assembly without removing the carb) I removed the top weight and spring (left ball with weight on it), reset float level to 16mm and she runs smoothly. No more stalling/flooding going over speed bumps. Ready to go wheeling again!     Anyone else experience this?     FYI - I had purchased a remanufactured OEM carb from Fc Remanufactured Product (National Carburetor) 18 months ago to replace the carb that was originally on my Sammy.

See/Reference "Help; What Happened?!" by riverrat in this same heading.

Unless you are required to meet your local/state pollution requirements. I highly recommend getting rid
of the OEM Carb set-up. I was always having problems with the ones I had including the last one which
was a "Factory Rebuild".

With the ECM constantly feeding it controlling signals, it can be a real nightmare
to keep them running right. (The ECM reacts up to 8 input sensors, which in turn runs your carb settings.
why do you think it has all them dam wires & Plugs hanging out of it)

I have had excellent results with a Weber Carb Kit for Sammy's. just make sure you install a variable fuel
regulator, and a fuel pressure gauge to keep rail pressure under 2 psi. (Both inexpensive items from Summit Racing)
This will allow to fine tune for elevation changes. (|removethispart|@ 8,000ft 21% less air!!)

CAPT

More out of curiosity than anything else ...

Are you sure you're looking at the right FSM, have the right rebuild kit, and that the carburettor in question is/was the original?  Is there possibly a supplement to the FSM that is applicable to your particular vehicle (based on the VIN/chassis number)?  These are the sort of details that only a dealer (or someone with considerable experience with that model) would know.

You see - over the years, (my first drive in a Suzuki was three decades ago, and I've owned several over the ensuing years), I've found that Suzuki used many carburettors with the G13 engine (and there are also several different versions of the G13 engine), some very similar and some not so similar - I've bought carburettor rebuild kits that were correct in every way but one - the accelerator pump diaphragm was square (four screw holes) rather than triangular (three screw holes).

On that particular car (a Swift) the carburettors for an 89~92 were very slightly different to that used on the '92~94 - outwardly identical (unless you knew exactly what you were looking for) and interchangeable, but required different rebuild kits and different adjustments.

fordem: Checked my vehicle ID model number against the numbers listed in the FSM and it is the correct manual. No mention of multiple carbs in the FSM. Based on tearing it down for the rebuild, it is identical to the schematics listed in the FSM and the rebuild kit. I scanned the internet but did not find a supplement to the FSM. Although, there very well could be one for the Sammy.  Anyway just glad it is running correctly. And was interested if anyone else in Samurai land had the same experience. Just thought it odd.

ales porter
i experienced the exact situation you described.
the factory manual and kit both spec the float at 8mm, so that's what i did.
if there wasn't a window in the float bowl i probably never woulda figured out what was happening.
by trial and error i came up with +- 15mm.
taking that thing apart a few times........ whata pain!
only bad i've found in the fsm so far.

rascott: Good point about the float bowl window so you can actually see the fuel level.
I'm more perplexed about why I had to remove the spring and one of the weights. 
Anyway, hope this info helps others.

rascott: Good point about the float bowl window so you can actually see the fuel level.
I'm more perplexed about why I had to remove the spring and one of the weights. 
Anyway, hope this info helps others.

the lucky person will find this post and save a headache.
my '89 kick carb is very similar functionally, but ever so slightly different- last gasp before injection one off, i guess.
that sping and weight is part of the accel. pump circuit? mabe?
used to run a weber, but had to smog every 2 years.
back to stock.....

rascott: You are correct. the spring and weight are part of the accelerator pump system and are referred to as the "injector spring" and "injector weight". 

Mine has all the parts you mentioned in it and runs great. Go figure. Did have a mixture solenoid go bad once and the screen filter inside has gotten gunked up.