megawatt

Fair enough

Can't you measure the one you have?

Pays to be methodical when rebuilding engines. Well done.

Chrome isn't stainless steel. It's mild steel plated with chrome. Try using a sheet of aluminium foil and a non abrasive cleaner. On stainless, I use solvol Autosol which is abrasive, but a very good polish. Whether your chrome rots from the inside or outside, eventually you should replace it with stainless steel.

Sounds like you didn't put it back together properly. Did you move anything on the actuator side? I assume it's a hydraulic clutch actuator?

Good luck mate. Can you post pix of thread before you glue valve in? And when you've finished?

Probably a future World Champion, not a popular one with the other riders though. Wasn't there someone else, very sadly missed, with similar credentials? Could make Moto GP slightly more interesting next year?

You may be lucky with the oil drain valve as long as your sump thread is reasonably intact and you get a good chemical metal or Araldite bond. Would certainly avoid any further sump thread problems! Personally I don't think you will have a swarfe problem if you do a proper fix with a helicoil. If you apply grease to the drill when drilling the old thread out and when tapping the helicoil thread, 95% of the swarfe will stick to the grease! Any swarfe that goes into the sump will stay there or if it gets picked up, there is usually a gauze filter on the pick up. Alloy swarfe is not normally a problem unless it gets into your clutch and you have an oil filter to stop that happening. Steel swarfe could cause more problems, but would still probably not circulate far from the sump! Once drilling and tapping is completed, pour oil in and allow to drain a few times into a filter/funnel and inspect for swarfe?

Good write up Alex.

Seen loads of M10, 8mm allen key bolts Stu. Never seen a M8, 8mm allen key bolt

There is a very slim chance that it has a M10 fine thread mate, with a 8mm Allen head. If it is M8 thread and 8mm Allen head, it's the first one I've ever seen !!! will check some M8s and M10s tomorrow.

Reply sent. Can you measure the diam of the thread, the allen head and the A/F of the hexagon drive (Allen key)?

An M8 Allen bolt has a 8mm thread, 1.25 pitch. Takes a 6mm Allen key to tighten it up. PM yer addy and I'll stick two in the post tomorrow. Stainless OK?

Probably got a couple somewhere? The bolt in the piccy looks a tad short. What is the max length you can fit in?

Look like M8. Are they both right hand thread? Got some stainless if you measure the length, under the Allen head?

To check for leaking/cracked carb rubbers. Get bike running on a fast tickover. Make sure no stray sparks around plug caps and leads, then spray rubbers with WD40. If leaking, tickover will change.

Firstly , welcome to the forum mate. Have you got a Haynes manual. Look at wiring diagrams and pictures of carbs etc. Post pix on here with your questions and we will try to help. The hose from the top of the engine is a breather hose that connects into the airbox. You don't need to connect it to anything if nothing comes out of it, possibly a catch can? The carbs are fed via a hose between 2 and 3 carbs. Sometimes you need a vacuum connection from the cylinder head inlet stub to open a vacuum fuel tap if fitted. Try joining "oldskoolsuzuki" forum , they know everything Suzuki, but it is difficult to get on the forum. I am not far from T Wells

And mine

Yes mate, like yours, clear sheet covers with stainless brackets

Have seen some on a cruiser that are just clear plastic sheet, brackets are obviously a bit more involved.

Ouch, think I'll make my own, outta stainless

Those look great mate. How much and where are you in the southeast?

If it's flooded, choke off, open throttle fully and spin engine over a few times. Then try to start with choke on and NO throttle. If still flooded, remove spark plug, spin engine over, clean plug and warm up the electrode over a gas ring. Replace and try again.

Nice one. I used a large Rawlbolt once. Another time , a grease gun.

If yer a softie, you could use a drill?