Well, I got the modified tensioner adjuster installed, rebuilt the carb again, did the front brakes, and reassembled all the rest. The battery was on a trickle charge most of the winter. Crank, crank, dead. I go get a new battery, install and everythings ok. Crank, crank vroooom. Once up the alley and back, and there's oil pissing out the top of the dam side cover. Now I get to tear it all apart again, try to save the new oil, spend the money for the dam gasket, and hope IT don't leak. This is what I get for trying to save $$ on gas. I'll just spend it on the dam bike instead.

I encourage you to check the screws that have washers on The clutch/engine cover and see if they are place on the right place. On the clymer manual they emphasize this so you don't get a leak.

I just did the tensioner mod and instead of buying another $17 gasket, I bought a $4 roll of gasket paper at Napa that i can probably get four out of. Traced the old one and it works great now.

HOWEVER, when I first put it back together, the bolts wouldn't tension up. I even snapped one. after draining the oil, pulling out the broken bit and and replacing the bolts with new ones, all is well. The bolts that Suzuki uses are notoriously crappy, but I could visibly see the stretch. anyone else ever break one of these?

Was that the DIY gasket?

groupus wrote on 03/17/11 at 10:27:49:

That is shockingly low grade, considering that the clutch cover also has the mechanical function to actuate the clutch through the little cam in there. If you look real close when you pull the clutch, you can see the cover flexing.