Alrighty, so while working toward an ultimate solution (which i'll do a big guide on soon enough, but it involves drilling a hole through them in the lathe and tapping a stainless grub screw through the "finger" bits) for those stupid clips, i noticed something. If you look into the throttle slides themselves, right down the bottom is a groove where the clip "snaps" into. On my left pair of carbs there was no o ring in that groove. These clips have never come off in 20,000km. On my right pair there is a 4.5-5mm o ring in the groove. Both of them come off within 5000km with monotonous regularity. Next time someone has their carbs apart presumably to replace these garbage items, could you please look to see if your slides have the o ring in them or not? I am thinking they are supposed to have them, but removing them could very well cure the issue for most, letting the clip sit much further into the groove that holds it in. Cheers!
no need to pull the carbies to bits, have a read thru my account here http://www.scribd.com/collections/3674639/Suzuki-GSX250F-Across-Carburettor-Carby-assorted-info-Mikuni-BSW27 in here is the complete parts break down of the mikuni bsw27 Complete mikuni bsw27 Carburettor parts diagram and Part numbers theres no mention in the parts manual of the o-rings inside the valve piston and from memory i have never seen one inside my valve pistons since the day i bought my bike about 7 months ago
