New relay in (30amp spot light relay) fused supply fed from the orange switched to the loose red white from the front and now working just puzzles me how the hell it worked before???

Is the bike now running 100%? i think with some of the safety switches being cut it was getting its power another way as ther's a few orange wires that run through the fuse box.

New float bowl seals and relay on and now running again mixture screws 1.5 turns out but still seems a little rich to me, what do you think to an extra .25 of a turn out

Yep, take a look on the banditalley site as ther is a load of info on carbs by 'PitterB'.

Cool cheers Chris, i'll have a read then wind em out a bit more. Hopefully should have the bodywork back for the second time this weekend, then i can get the graphics on and put some more pics up.

hi the rule of thumb for floats is invert the carbs and set the height that the seam on the float is parallel to the carb body/ float bowl sealing face then increase height 1mm as for that rubber bung it should be tightish fit else it does not seal if it swells it the petrol then the rubber is finished and it should be replaced most times it hardens and shrinks an easy fix is use a 4/5x1 o-ring on it remember all o-rings used must be fuel resistant or they will leak as for relay here is the scoop the early bandits had the regulator connected directly to the battery but the regulator would drain the battery while the bike is standing to below 12.2vdc so most bandit would over time start suffering starting problems a temp cure is to use the YTX9-BS battery instead of the YTX7-BS but trouble would return months later so Suzuki instead of changing the the regulator setup of old (and Honda style) of having internal circuitry that would switch off the unit they added the relay so when bike switched on it would connect the regulator to the battery so you can wire up and relay that can handle 30A+ that will swith at 8-15vdc on (most relays say 12/12.5vdc but will work with voltage 8.5-16vdc) so if that part dies you get no charge

for mix screw std is 1 3/4 (carbs that dont use rubber plug and 30 pilot jet) turns to 2 1/4 turns (for carbs that use 32.5 pilot jet and rubber plug)

most carbs and manuals say slide needle must be 3rd/4th notch from top i find that at sea level set slide needle 2nd notch from top sorts richness out and use CR8EK plugs NOT the CR9EK