Well, it'd been a few busy days. While waiting for the new gaskets, I decided to clean the carbs the right way, and took it all apart.
Once it was all back together, I tackled the broken choke tab I discovered when I removed the tank. The PO used a zip tie on the slider to hold the choke cable in place, as the tab on the carburetor was broken off. Needless to say, this did not work overly well.
Instead of messing with the carburetor and risking warping due to welding/soldering, I went a different route - cut off the tab on the choke rail and move it over to the side, so i could use the next available tab on carburetor number one. Here it is all welded together. The choke cable is long enough to allow this, and it is much safer than messing with the carburetor itself.
Of course, most of the spacers on faring rubber mounts were not there. Surprise, surprise! Instead of waiting for Suzuki parts, I had new spacers made at a local machine shop. Now the fairings atttach the way it should have been all along.
I then put everything back together, replaced fuel hose, and breather hoses, and bench-synched the carbs. The bike started right up, as it should with freshly adjusted valves and carbs. The pilot screws, however, were a mess, and idle was erratic. I started with a base setting of 2 turns out, which was not good enough. In the end, after a few 'ouch' moments from touching hot engine while adjusting pilot screws, I ended up with 3 1/4 - 3 1/2 turns out. Idle is nice and stable and bike runs as it should.
Fresh oil and fresh oil filter in place, I took it for a spin. Everything seemed okay, except for faint chain noise.
Upon my return home (a quick one), I looked for a cause. Voila, the clutch master cover was bent and it was touching the chain - not making any noise unless one was riding it.
This was cause by me, pressing the clutch lever with the sprocket cover off the motor - I was messing with the carbs and needed to press the lever to override the clutch switch.
Fortunately, other than some rub mark on the chain and a new four Dollar part, noting was broken.
Here are the two parts together:
An easy fix!
I'm getting my new Pilot 2's mounted tomorrow, and then I'd like to change the fork oil. After that it should be all sorted out.
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