Help needed with extra screws left over

tgeliot said:

I should mention that I had a LOT of the bike taken apart, in order to replace the (ABS) brake lines.

I have what seem like at least pretty appropriate parts in all those holes, but I'm still left with the following:
View attachment 316146

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Topher, since you worked on the brakes, is left-over bolt C supposed to be holding the caliper on to the forks? Does bolt C thread into nuts A?
Did you remove the plastic cover that goes around the base of the engine (bash plate area)? If so bolts B look like the ones that hold that in place.
Bolt D almost looks like the bolt holding the front of the gas tank in place.... but that requires a nut, and those nuts look too big for that bolt.
Having two loose nuts probably means you got one of the two bolts those go to back into place but didn't put the nuts on. Again, since you mentioned brake work, I would suspect caliper bolts.
Bolts B and E look as if they are for holding on the tupperware -- not really essential, but still important. Bolts C and D, along with nuts A would cause me to tear down everything that i just put back together and start over. Missing installation of those parts would give me great concern and I'd keep the bike off the road until I found unfilled holes for them.
When you figure it out, let us know where they were supposed to go.

The shoulder bolt #2 is used for securing plastic panels without crushing them. They are used in panel holes 2,3, &4.
The fact that you have only one left means that you have used them elsewhere.

Bolt #4 will be used for securing a thicker panel without crushing it.

Bolt #1 looks like one of the bolts that holds the plastic panel at the front of the tank (at the top of the forks tunnel).

Bolt #D does look like the front fuel tank securing bolt, although possibly too short.

Bolt #C will be part of the brakes.

You really need to disassemble everything you removed and start again, looking carefully at each fitting and its matching securing bolts. Those shoulder bolts are intended to hold something (usually fragile plastic panels), without applying pressure and crushing them.

Bolt #3 though is intended to act as a vibration damper for whatever it secures.

I have a set of magnetic cups.
They stick to metal - and nuts, bolts, and washers stick to them.

Some of the parts listings will show you good clear photos of the screws if you click on them, but not all. That can be a real PITA.

Even when they have photos, for some reason the metric hardware is often shown next to an inch ruler, which isn't super helpful. I don't know why PartZilla does that.

The parts listings occasionally state the shaft size and length of the fastener, i.e., "Screw 6 x 22" means an M6 screw (6mm nominal shaft dia.), 22mm length.

Screws 1-4 and B are all for securing plastics.

Screw 1 goes in hole #2.

Screw 2 looks like it may be the shoulder screw with a conical head. Those go in the #1 holes, forward and aft of the turn signal, through the shiny black plastic side panel. They are unique on the bike.

Screw 4 goes in hole #4. These are unique to the black plastic panels under the rear half of the fuel tank (Frame Cover in Suzuki parts-speak):

Suzuki 09139-06107 - SCREW | Partzilla.com

B look like they are the big-head screws that go into the lower side cowling, threading into fittings in the radiator sides. But I think you said you already put screw #3 in that place?

The remaining hardware goes elsewhere.

Nut A (whiz/self-locking type, w/flange) I'm stumped by.

There is one on an end of the long bolt at the front of the tank (where you can pivot it up for service once the plastics are off), but I think you stated in your other thread that it is in place already.

Bolt C looks to me like one of those that hold the front master cylinder to the handlebar - #9 here:

Suzuki Motorcycle 2008 OEM Parts Diagram for FRONT MASTER CYLINDER | Partzilla.com

Bolt D: could it be #9 here, since you did stuff with the brakes?

Suzuki Motorcycle 2008 OEM Parts Diagram for REAR CALIPER (DL650AK7/AK8/AK9) | Partzilla.com

As the others said, I would go over everywhere you removed stuff, to make sure no fasteners are missing. You don't need brake system parts moving around that shouldn't, or handlebar controls shifting while you ride.

By now you've learned that some of the hardware was substituted by PO. I can understand why people do this. Many of the fasteners are not available at a local hardware store, or even from a specialty vendor like McMaster-Carr. The shouldered screws for the plastics are particularly exotic.