Even with the pics on the Handyman CD, I had a hard time fitting the original airbox back into the bike yesterday. Suzuki engineers did a thorough job with the very close fit in the frame, and with the design of what part of the cable harness needs to go where. Put one cable/connector in the wrong place, and the the airbox (and the battery box!) will never fit Also, you wonīt believe the amount of homebrew side panel fasteners and other ad hoc stuff I found. Homemade angled brackets, strange bolts..and I also found a miniature circuit breaker for the ignition hidden behind the LHS panel.

Well, airbox in place, BSM exhaust/muffler in place, carb rejetted. One more hour of work on the bike, and then itīs time for a road test, and mixture adjusting time. Once everything works OK, Iīll tie the cables down properly to the frame and leave the bike alone.

BSM? German slip-on stuff. The muffler is louder, it kinda barks. Very much "in your face" sound without being a total nuisance to the neighbors. FYI.

Edit: one more thing: the local shop was out of larger idle jets. The shopkeeper has been in the 2- and 4-stroke tune-up/blueprinting/dragracing business for 30+ years, and he noted - in passing -  that it is very rare that the idle jet needs to be changed, especially with stock air filters. He means it just upsets the tuning equation. The mixture screw should do the job, he says.  So I will go for the stock 47.5 and the 152.5 main and do some thorough testing.

Yep. I know, I know, and Iīve been reading every single thread about it. Now, I donīt mean to disrespect the opinion and knowledge of lots of you guys, I just want to try it out before I go and split the carb again and install a larger idle jet. Itīs the researcher in me who wants to do some empiric testing.

And..after all, the guy has been into performance bikes professionally (has a Dyno bench etc etc) for almost 4 decades, he canīt be just talking BS.

If it ain't broke, don't fix it!