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Got my carbs back from the suzuki shop (Iknow, stupid move) and my block back from the machine shop yesterday. put the motor together today. Used hose clamps for ring compressors. center pistons first. Went in like a dream, then realized the cam chain tensioner was still flipped forward under the block.
So back off comes the block. Think those darn pistons would go back in? After much cussing and running from one side of the bike to the other the block finally went on. Threw the head on, no problem. torqued it down, threw in the cams, torqued down the cam caps. Adjusted the valves. OK, ready to slap the valve cover on, and...wait a minute. Where did that cam end plug go?? I know they were all there when I painted the head. I popped them all on the head last night. Searched the garage for an hour with a drop light. under everything, scoured the floor and the workbench and the toolboxes. Nada.
Oh fudge. The only place left it could be is in the motor somewhere.
Off come the cam caps, out comes the exhaust cam. There it is! stuck under the exhaust cam in the corner over the #4 cylinder. Couldn't see it under the cam with the drop light, I looked there. Anyway, at least the head didn't have to come off. ( Worse thought is it went in the da** bore when I put the head on.)
Anyway, back together, on with the valve cover, threw on the stock exhaust for a test fire, put the rack of carbs on, drop the tank on, start crankin her over and....the carbs are leaking gas all over my newly painted transmission.
. Pulled the carbs off and blow through the fuel line while the carbs are upside down and there is a leak from the fuel rail where it exits the #2 carb to feed the #1 carb. 
My front sprocket cover is now vertically striped black/aluminum. Why do I bother?
So back off comes the block. Think those darn pistons would go back in? After much cussing and running from one side of the bike to the other the block finally went on. Threw the head on, no problem. torqued it down, threw in the cams, torqued down the cam caps. Adjusted the valves. OK, ready to slap the valve cover on, and...wait a minute. Where did that cam end plug go?? I know they were all there when I painted the head. I popped them all on the head last night. Searched the garage for an hour with a drop light. under everything, scoured the floor and the workbench and the toolboxes. Nada. Oh fudge. The only place left it could be is in the motor somewhere. Off come the cam caps, out comes the exhaust cam. There it is! stuck under the exhaust cam in the corner over the #4 cylinder. Couldn't see it under the cam with the drop light, I looked there. Anyway, at least the head didn't have to come off. ( Worse thought is it went in the da** bore when I put the head on.)
Anyway, back together, on with the valve cover, threw on the stock exhaust for a test fire, put the rack of carbs on, drop the tank on, start crankin her over and....the carbs are leaking gas all over my newly painted transmission.
. Pulled the carbs off and blow through the fuel line while the carbs are upside down and there is a leak from the fuel rail where it exits the #2 carb to feed the #1 carb. My front sprocket cover is now vertically striped black/aluminum. Why do I bother?
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