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Gooseman - to the first post, I know wire might not always clear it but I have checked it pretty thoroughly, it is a crisp circular hole unlike it would be if it had gum on the walls you know, but I will check again to be sure i'll see if I can get a drill bit in there to ream it out. To the...

The only place there could be a vac leak is under the fly wheel, can I spray something on it to check for an idle change? I would be surprised if the pilot jet had anything left in it, with the amount of carb cleaner + compressed air + wire that has gone through it... I can pull it out again...

Chronic I think that was WD40 from when I was spraying it down the throttle cable cap, I think... But it has been running rich, the idle is set on the rich side. Either that or it got in there when I opened the fuel **** with the fuel line disconnected I don't know lol. I ran it again it's not...

This is with the idle speed set to a nice idle with the air screw 1 turn out - quite rich, so quite high idle setting; This is with the idle screw removed, i.e. the slide sitting on its stop; Obviously the arch is lower at the front, closed is pretty well closed it's a little higher at...

I stood the bike up, with it idling, dumped the gearbox oil into a container, let it idle for a few minutes like that, put bung back in and re filled it, no change to the idle the entire duration... Tried squirting a bit of WD40 around that throttle cap housing and it did look like it was...

Not sure about either jets, I've never had experience with jetting. It's had the same ones in it since the day it left the factory I would think. And it used to run great I use to hammer it as a kid and it never gave me trouble - I didn't bother wondering about jets for that reason.

And standard injector setup yes, I ran premix for a while, after putting it back together, until the pump primed itself, I took it for a run on premix with the oil line off and watched it dripping nicely, and hasn't seized yet, I have no reason to doubt it. I'm fairly sure the hose is sealed...

I asked a guy at the suzuki dealer about that boot, he said it's not usually a problem but I doubted that too, tried wrapping it in insulation tape (tonnes of it..) and got it sealed nicely... Exact same problem... Good spotting though..

my67xr, get ready for a tedious video haha.. Sorry if these videos are just a pain let me know, but I figure you'll understand better if you see what I'm doing + results. I didn't do exactly what you said the first time, I had it in positions which would demonstrate what is going on best...

And the vacuum test while idling... I can't hear the engine change but I don't know what I'm listening for really. http://www.youtube.com/watch?v=uQyzra-a3mg One thought that crossed my mind, the crank seals did hold pressure but I did this test cold, would it be possible it is developing a...

Lets disregard what I said about getting through the mid and opening it nicely on the top end cause I can't even get it to do that any more, maybe it was just that day, I think I had the slide needle on the lowest richest clip... I could go out and lower the clip to full rich and it would still...

Ok so these videos are the same ride just then, copper ring is in, gasket is under carb etc, it should be running right in theory i.e. I'm not missing any parts. Vid 1... Air screw Full rich (i.e. fully IN). Slide needle on middle clip (where it used to run fine)...

I opened a spark plug right out to 5mm or so, it sparked every time bright and blue there isn't anything wrong with it at idle that's for sure. I took the coil temperature before starting which was 13.5°C (or 56°F for the yanks ;)). I got back after a 10 min ride and it had only gone up to...

I will have a go now at the spark plug test too, got plenty of old dungers around that I can break. Catch you soon

Hi Craig, I have put some thick paper gasket between the intake pipe and cylinder manifold, I'm pretty certain it is sealed up but I will try the vacuum test on it again thoroughly if it's still producing these results. I've sanded the face back so it is nice and smooth the tips of the flange...

I wonder if it might be the intake pipe have a look at these photos, it is a little out of shape. I would have thought if this were the case that the WD40 vacuum test would produce a result. I will get it as flat as I can get it and put a gasket in there, see how we go. It's going back together...

I have pulled the barrel already I didn't think to look specifically at the reeds but from what I remember they looked pretty clean. I can start the bike with my hand it has no trouble. Still running the baffle yup, I've checked it for carbon I used to get the little nuggets building up in the...

Chronic I have cleaned up that manifold it is in bad shape admittedly, I gave it a good clean with some petrol and got it as good as I can get it, it is flat and I'm pretty sure it is making a good seal but I could try making a gasket for it - I will try that tomorrow before I take it for a...

I have checked the pilot circuitry as well, I thought it was the carb too believe me I have put a lot of effort into it, it has been disassembled to it's smallest possible components (including pilot jet out) more than one time and I haven't just doused it in carb cleaner I've made sure it is...

Haha amazes me how many guys our age I see posting about DS80s... As in all ages > 13... Don't tell me you own them for your kids I see right through that... hahahaha. I've had my fair share of DS80 induced bruises over the years too. And friends of mine... No matter how many times you tell kid...