SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Fabricating my saddle bag supports. :) /cgi-bin/YaBB.pl?num=1216639715 Message started by 4carbcorvair on 07/21/08 at 04:28:34

Title: Fabricating my saddle bag supports. :) Post by 4carbcorvair on 07/21/08 at 04:28:34 I finally got to tackle my my saddle bag supports. I used the thread in the tech section on making them. I bought some round and flat stock from Lowes, printed off the picture with measurements and got to work. One modification I wanted to make, was to allow them to be REMOVABLE. I don't need them everytime I go out, and do not care for the looks of them just hanging there not being used. First thing I did was look under the fender for mounting. My 2007 S40 does NOT have a rear mounting bolt on the side bars, there is simply a pin that is welded onto the stock side bar that goes through a hole with a grommet in the fender. http://i81.photobucket.com/albums/j233/4carbcorvair/S40%20bike/S40Bike014.jpg What to do? I got looking around and decided to use the mounting bolt towards the front to mount a small bracket that will stay on the bike. What to do about the rear? I made another small bracket that will mount using the same hole that the turn signal uses, which is mounted to the side bar. The screw is a bit too small, I'll have to find one a little longer. I had some stainless bolts, picked up some wing nuts and lock washers. First thing was to bend the round stock. One piece was just long enough with a little extra. http://i81.photobucket.com/albums/j233/4carbcorvair/S40%20bike/S40Bike011.jpg http://i81.photobucket.com/albums/j233/4carbcorvair/S40%20bike/S40Bike012.jpg I welded 4 bolts, 2 to the rear mounting bracket on the bike, would have preferred on the support, the way I made it, there was a clearance issue. I don't want these to be very visible when the supports are off.  2 on the saddle bag support. I welded everything up, than painted them. Did a little 'tweaking' on them before paint. They are drying right now. I'll get some pics up later with them mounted on the bike. Not sure if I will get to them today or not. http://i81.photobucket.com/albums/j233/4carbcorvair/S40%20bike/S40Bike013.jpg

Title: Re: Fabricating my saddle bag supports. :) Post by Mr. Hyde on 07/21/08 at 08:48:36 The saddlebag support locations and the OEM supports for a 2007 are quite different from the information given in the tech section. Those photos and measurements are for bikes pre 2005. The mounting points designated by Suzuki for the 2007 are the mid point bolt behind the fender brace to the bottom bolt near the shock. The configuration of the supports themselves are considerable different. http://w3.bikepics.com/pics/2008/07/21/bikepics-1360327-240.jpg

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/21/08 at 10:52:30 Hyde got that correct. My 07 uses the front and rear bolts on the rails... I'll take a picture of my rails when I get home to give you an idea of how they look compared to the pre-05 models.

Title: Re: Fabricating my saddle bag supports. :) Post by 4carbcorvair on 07/21/08 at 12:54:39 Well, this is good to know now....  ;D ;D ;D I may have to modifications.....  :-X ;D Pics would be great. Thanks!!

Title: Re: Fabricating my saddle bag supports. :) Post by forrest on 07/21/08 at 13:39:45 Just curious, whatever happened to the guy who was thinking of using file folder supports?

Title: Re: Fabricating my saddle bag supports. :) Post by PerrydaSavage on 07/21/08 at 13:55:08 Discovered just this weekend that the bag support requirements for the S40 are different than the dimensions I originally posted up for the Savage brackets from several years ago ... made a set for my '03 and the original dimensions fit perfectly on that Bike ... If anybody has an OEM set of "next generation" bag brackets, I'm sure your fellow LS650'ers would much appreciate some diagrams and dimensions for the S40 bag rails pic'd above!

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/22/08 at 09:15:42 Perry - I'll try to document my supports today either over lunch or when I get off work. Here's a shot I found on BikePics: http://w3.bikepics.com/pics/2008/07/21/bikepics-1360327-200.jpg I'll get some actual shots of my bike along with some dimensions too. edit - I see this pic was already posted above. Oops! :-P edit 2 - It's my guess that the brackets from the Savage WOULD work on the S40. The sissybar and rails swap over, so why wouldn't these brackets swap too? The grommet in the fender can be removed. The bolt for the sissybar goes into there. I don't know how the original "non-sissybar" rails are for the Savage, but maybe a bolt went there too, which is how the got these original brackets to mount up. At any rate... I'll get info up shortly. :-)

Title: Re: Fabricating my saddle bag supports. :) Post by motokid on 07/22/08 at 09:40:09 Hi, it would be nice if somebody could post pictures how OEM sissy bar kit for S40 (after 05) and its mounting hardware look like, both package and mounted. thks, K

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/22/08 at 12:19:15 I'm pretty sure it's exactly the same as the Savage kit... There are a few pictures I found over on BikePics.com of an S40 with the sissybar. The brackets look exactly the same... The only differences I can find are the pad, being covered with the new material on the front, and the emblem on the back of the bar being a "Boulevard" instead of "Suzuki"... I'd like to order one of the new ones, if I could find someone that had a set in stock. But, I've come up empty handed in my searches.

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/22/08 at 12:27:59 http://w1.bikepics.com/pics/2006/05/06/bikepics-580871-800.jpg Here's an 05 with the sissybar. You can tell it's the S40 "model" by the covering on the front. It looks exactly like the brackets from the Savage. http://w2.bikepics.com/pics/2007/08/08/bikepics-987497-800.jpg Boulevard emblem on the rear, vs the Suzuki on the Savage models. Here's an up-close look at the brackets from another S40 owner over on BikePics (big shot) http://w2.bikepics.com/pics/2007/07/11/bikepics-959289-800.jpg

Title: Re: Fabricating my saddle bag supports. :) Post by motokid on 07/22/08 at 14:55:13 Great, thks a lot. What kind of muffler is that (on the black one)? K

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/22/08 at 19:35:35 I checked his BikePics page some more, but it didn't list anything specific under those pics. You can send him a message if you want: http://bikepics.com/members/necropsy/05boulevards40/

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/23/08 at 18:28:01 Alright... Sorry for the delay, just was busy yesterday and finally got around to getting these specs today while installing my Big Crank battery. From the picture above, I'll try to give a basic idea of what's what... The brackets come out from the fender 3", it's almost even with the rear springs. These are all rough measurements, because I wasn't sure how to calculate in the bends. The front "bar" was 4.5", the bottom bar was 5.5" and the rear bar was 6". As stated, the front bar connects to the furthest forward bolt and the rear bar connects to the rear bolt of the S40 rails. Hopefully that'll help. I know it's not the best, but it should give you a basic idea...

Title: Re: Fabricating my saddle bag supports. :) Post by PerrydaSavage on 07/24/08 at 00:20:32 thanks Bandit ... gonna copy those dimensions down later ... the S40 bag brackets are shaped differently than the older Savage brackets ... the S40 ones are angled to follow the rear shocks 'cause the forward mounting points are further ahead than those for the Savage ... at least it seems that way to me! :)

Title: Re: Fabricating my saddle bag supports. :) Post by justin_o_guy2 on 07/24/08 at 04:18:17 I decided to stick the Givi soft bags that I had on the Guzzi Nevada on Bull ( the Boulevard). They fit under the rear lights & are up against the shocks. The left side is kept out of the belt by the recently reinstalled belt guard. The bag means the helmet lock is nonfunctional, so I removed it & bent a piece of 1/8th piano wire in a z to fit in the front hole the lock was mounted in, so as to not mess up any threads, & formed a loop & stuck it under the lower nut at the front of the fender brace. Other bags may not be so easy, but now I have what I need to haul enough stuff from the grocery store the guzzler can stay home. Compared to the bike, even the Civic at 30 MPG is a guzzler.

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/24/08 at 08:11:40 Perry - I'm pretty sure the mounting points are the same from the Savage to the S40. I mounted the Savage rails for the sissybar on my S40 and everything lined up properly.

Title: Re: Fabricating my saddle bag supports. :) Post by PerrydaSavage on 07/24/08 at 13:52:54 Ya could be right Simon ... must be my eyes or somethin' 'cause the S40 Bag bracket mounting points look closer together than those for the Savage pic'd on the 1st page of this Topic??

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/24/08 at 13:59:13 The Savage brackets are using different holes to mount the brackets on. Compare the Savage: http://w1.bikepics.com/pics/2006/05/14/bikepics-587758-800.jpg and the S40: http://w2.bikepics.com/pics/2007/07/11/bikepics-959289-800.jpg The FRONT of the bracket on the Savage, is actually the REAR of the S40 bracket. The REAR of the Savage brackets are using the rear hole in the fender. 4carb posted that in his first picture, where on the stock S40 that hole is filled with a grommet... I wonder if the original Savage rails included a bolt back there, instead of the grommet and "nipple" on the rail?

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/24/08 at 14:07:40 Hmmm... I just went through all of the years of Savage pics over on BikePics.com. It looks to me that ALL Savages came with a sissybar installed. I only found ONE bike that had non-sissybar rails posted, out of 100~ bikes, and those looked like the guy may have swapped S40 rails onto his bike. That would explain the switch in design too... If the S40's would've all come with sissybars installed, they could've kept the design the same.

Title: Re: Fabricating my saddle bag supports. :) Post by 4carbcorvair on 07/24/08 at 14:18:54 That back mounting point is different, I've mentioned it before in the past and it seems I'm not believed. I have Savage rails here, the last hole on the fender is used for a bolt on the Savage. On the S40, there is a pin that is welded onto the side bar that slides into the hole in the fender with a gromet. No bolt on the last hole. I'm not saying they cannot interchange, just that there IS a production difference. I think I'm going to order the S40 saddle bag supports, do it and be done. :) This pic on Suzuki's site for accesories, shows the further ahead mounting for the saddle bag supports for the S40. http://www.suzukicycles.com/Accessories/detail.aspx?modelId=02c35834-7fdc-4fbe-a150-c2675d56227b&accessoryCategoryId=&accessoryId=d4921c27-1474-4f3d-ae28-f34c5db24570

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/24/08 at 14:30:47 4carb - I've said the same thing as you... I've swapped my S40 rails for a set of Savage rails. I agree with you 100% there IS a production difference. From what the pictures tell me, that difference is that there were no non-sissybar rails for the Savage.

Title: Re: Fabricating my saddle bag supports. :) Post by SimonTuffGuy on 07/24/08 at 14:37:14 BTW... Check our EBay for those brackets. I found several Suzuki dealers that are using EBay to sell their stuff, with a decent price cut. I got the brackets for $59 compared to the $79.95 that was stamped on them MSRP. http://stores.ebay.com/SUZUKI-PARTS-OUTLET I got mine from this particular seller, although it looks like he's out of them. There are some via this seller and you'll still get off cheaper than MSRP: http://cgi.ebay.com/Saddlebag-Supports-S40-05-06-LS650-up-to-04_W0QQitemZ350073952214QQihZ022QQcategoryZ35580QQtcZphotoQQcmdZViewItem

SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved.