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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> My Build Thread /cgi-bin/YaBB.pl?num=1238173732 Message started by SimonTuffGuy on 03/27/09 at 10:08:52 |
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Title: My Build Thread Post by SimonTuffGuy on 03/27/09 at 10:08:52 I've seen a bunch of other members with a little build thread or a place they post pictures of their stuff... So, here's one for me! The Savage takes on a whole new look with the tank removed. This is the first time I've had the bike more apart than removing the seat (or pulling the battery): http://www.pimptiva.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=2625&g2_serialNumber=2 http://www.pimptiva.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=2628&g2_serialNumber=2 Current mods that I'm working on include: -diamond jim exhaust -carb rejet -relocate turn signals and tail light to under the fender (I've got a spare fender for that - $10 off EBay with local pickup... Score!) -side mount license plate of some sort -new saddlebag install More to come... |
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Title: Re: My Build Thread Post by diamond jim on 03/27/09 at 13:10:27 Leave the tank off and use the hollow frame to hold gas. It would be about the same volume! Did you fab a longshot pipe mounting bracket yet? I think each mod has at least one catch point that makes it difficult. For the pipe it's the mounting bracket. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 03/27/09 at 13:27:05 I didn't fabricate a mounting bracket yet for the pipe... I'm thinking of going with a small L bracket cut to size, or I'll end up using the 1" squre tubing like you did (that was the suggested method from the exhaust shop). I want to get the carb tuned before I ride it anywhere (more than in the back parking lot). |
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Title: Re: My Build Thread Post by SimonTuffGuy on 03/27/09 at 14:31:01 Carb is off... Got the bowl dropped and switched to the 152.5 main jet. I'm going to leave the pilot jet alone for right now and I am going to do a 1/4 spacer on the needle jet. I busted 2 screw drivers in an attempt to get into the needle jet area... I put a little bit of PB blaster on them in attempt to break them free, but I'll have to find another good screwdriver before I attempt it! |
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Title: Re: My Build Thread Post by Texas-1-lunger on 03/27/09 at 14:34:57 Where did you get the crash bars at they look wider than mine. |
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Title: Re: My Build Thread Post by diamond jim on 03/27/09 at 15:16:02 003A3E3C3D0726353514262A530 wrote:
Sounds like a good plan with the jets. You already know about the allen heads for the carbs. Get some M5 allen heads to replace the stock ones. Search the forum for posted length and pitch. I've done about 6 jet changes with the stock screws and removing the carb. I recently did the allen heads. Last jet change took maybe 4 minutes and no carb removal. Sweet. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 03/27/09 at 17:19:34 Bars are Wingerline from Accessories International... Much nicer than stock bars! DJ - that is the plan with my bolts too! |
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Title: Re: My Build Thread Post by odvelasc on 03/27/09 at 17:52:30 Try getting a nice little 7 inch heat shield for that awesome exhaust. I bought mine for 15$ at my local shop. Should be about the same at JC whitney. Dont forget that you also did the cone filter there. Why do I see two cone filters in your pick, and how is the carb and everything held up now? |
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Title: Re: My Build Thread Post by diamond jim on 03/27/09 at 18:24:35 666D7F6C65687A6A090 wrote:
A clamp holds mine on good. See the post below. (Edit: trying to cosolidate and not to post so many pics). |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/01/09 at 07:20:32 I need to finish the exhaust before I worry about the headshield. Things have been crazy at home the past few days. Personal News: 1. Closing on our house on Friday 4/3 @ 4:30 (YAY!) 2. Aden, our little 8 week old shetland sheepdog (sheltie) puppy came home on Saturday With those things... Spare time for the bike has been minimal. I got the top of the carb off yesterday... It was after stripping 2 of the top bolts (ugh!)... Replacements will be going in before it goes back up. diamond - What is that in your picture and how does it hold the carb in place? |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/01/09 at 07:23:43 odv - the 2nd filter is for the crank case vent hose that went into the airbox before. That's not the final location, it was a temporary holding place while I moved the bike around. |
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Title: Re: My Build Thread Post by diamond jim on 04/01/09 at 07:53:55 It's a piece of aluminum wrapped around like a cable clamp with the inside tabs angled to line up with the rear left diaphram cover allen head. It's sturdy but more or less just stabilizes the carb since the carb/engine coupling does a great job holding the carb in place already. The inside of the clamp is lined with electical tape. Took a little playing around to get it shaped just right but it works like a dream. I might paint it but for some stupid reason I like that little piece of shiny there! http://i255.photobucket.com/albums/hh128/russ_diamond_jim/carbsupport.jpg http://i255.photobucket.com/albums/hh128/russ_diamond_jim/59.jpg |
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Title: Re: My Build Thread Post by sakara on 04/01/09 at 08:50:56 Nice idea; thanks for the tip |
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Title: Re: My Build Thread Post by PerrydaSavage on 04/01/09 at 15:14:06 A diagram with measurements of those Wingerline bars would be appreciated ... would like to get a facsimile made up out of electrical conduit ... danke! 8-) |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/01/09 at 18:10:13 I'll see what I can do. Got a bunch going on the next few days with closing on my house and moving. :-P FWIW... Got the jets finished up this afternoon. I went without any spacer up top. Suggestions on this? Should I go back in and put in a spacer or two? I will say... It was a huge pain to be working there, but I got it. Tossed everything back together and re-mounted the tank to try a test fire up. It started good, ran fine, etc... I didn't go out for a spin since I need to finish up a few other little things first. I might put it back together to try it tomorrow to see how it goes. I need to finish up the exhaust so it's ready for spring. More to come later. |
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Title: Re: My Build Thread Post by ineclipse on 04/07/09 at 16:26:06 wild air filter mod. what you got there? |
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Title: Re: My Build Thread Post by diamond jim on 04/07/09 at 20:53:58 The blue cone filter is his oil breather/crankcase filter. The larger one is his intake air filter. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/08/09 at 05:44:35 diamond jim got it... The blue filter is for the crank case vent that previously went into the airbox. Got a ride out on Sunday. Got a chance to get it on the road to see how she rode. Overall, pretty good I think. I'll have to check the plug to see how it looks and to make sure that I'm not too rich or lean though. And I need to get the exhaust finished up so that there's no leak (I think that had a good bit to do with the ride). On decel, it wasn't backfiring or popping like it did before... But, there was something noticable going on. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/16/09 at 17:31:46 Well... I finally got the time to run the bike back out to the exhaust shop where they finished up my diamond jim muffler setup. They ended up bending a whole new pipe for me with the bike there. Fits great. The shop welded a nut to the pipe and then mounted it to the stock hanger instead of using any sort of mount or steel tube (similar to diamond jim's way). The baffle is right after the bend. Again, the shop welded the nut inside the baffle and then threaded the bolt in to hold it all in place. http://pimptiva.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=2631&g2_serialNumber=2 http://pimptiva.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=2634&g2_serialNumber=2 http://pimptiva.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=2637&g2_serialNumber=2 http://pimptiva.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=2640&g2_serialNumber=2 Next up is painting it and then the chrome heat shield. The sound is nice... It's a lot quieter with the baffle installed. I was expecting it to be much louder, but it's pretty tolerable, and at cruising speeds, seems very similar to the stock exhaust (not highway cruising speeds... but at 45-50). The best part is that I'm pretty sure the carb setup I went with is pretty good. I'll have to pull the plug to double check, but it seems great. I was a little unsure on the way out to the shop... It stalled. I was thinking that the carb was flooding, but turns out that it just needed filled up. Not riding for a few months got me out of the reserve tank habit! :-P Next on the list... Get the license plate mount on with the plate... Get wires run down to that and light it up (have a spare led lamp from my Jeep that I'm going to run)... Then wire up the led brake light and new rear turns and it'll be good to go for spring! I'm excited. The weather is supposed to be nice tomorrow... So I'm planning to ride into work. Still need to tackle a few little projects, securing some wires and all, but it'll make it the 6 miles into work. :) |
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Title: Re: My Build Thread Post by diamond jim on 04/17/09 at 08:49:04 That looks sweet. I like how they did the mount. I painted mine with some gloss high heat black paint that I got from Lowes. After painting, I noticed that the paint would get a little soft and a ltacky after the first 3-4 rides. During this curing process, if somthing gets on the pipe, like a piece of grass, don't wipe it off when the pipe is hot. Wait for it to cool then it will either fall off or wipe off easily.Otherwise you might smudge the paint. After a few heat ups and cools downs the paint will harden and all will be fine. |
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Title: Re: My Build Thread Post by justin_o_guy2 on 04/17/09 at 09:55:30 The exhaust being out past the brake arm is nice. The Trapp puts soot all over mine, I guess Im a bit rich in some part of the RPM range. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/17/09 at 10:06:02 Thanks for the tip(s) diamon jim! I'm pretty happy with the end reults too. I think at some point I'll try my skill at doing some sort of slash cut on the end similar to yours... Just not sure how I want to do it yet. I'm going to check for some high temp paint tonight. And see what I can do. It's supposed to be a beautiful day tomorrow, but I'm stuck moving computer equipment for work from the current building were in, to our new operations center. |
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Title: Re: My Build Thread Post by diamond jim on 04/17/09 at 11:25:45 The taper does change the sound some. I like it better. The gurgle sound on decel is not so abrupt and rough but rather smoother and more refined. For painting tips, check this out: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1239992423/0 |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/20/09 at 17:48:54 Thanks for that thread, that's good info. This weekend would've been perfect weather to paint, except that I was in the office for 16 hours moving servers to our new operations center. diamon jim... Question for you. I've looked at your pictures, but I can't quite gather where mine is different. With my saddlebags, they sit right along where yours do... But with my sissybar rails and stuff, my stock turn signals still fit. I know you said that yours didn't. The top of the bags rubs a little bit when you go to open it, but the bags don't prohibit the signals from being there at all. Any reason yours didn't fit? Also - the bags don't cover the rectifier at all. The straps go right behind it. The only thing I'm going to relocate it the wiring that runs into the fender. It seems like that is the only thing holding up the final install on my bags. I've got to finish up the wire hiding on the bike, decide what I'm doing with my battery (and box), and get the magic sh!t box secured. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 04/30/09 at 18:01:47 Got the box mounted... My cables came in for the mini apes that I ordered. I'm not really sure WHAT look I'm going for here... Haha! I got my new license plate bracket. The one I got off EBay was too short and hit the belt guard. The guy that made them created me a custom one, about 2" longer to clear everything. It looks great, fits perfectly. I'm thinking of removing the belt guard. Can someone tell me what's involved? Is it just pulling the nuts and taking it off? Or... do I need to add washers somewhere (I saw this in another thread)... Pics of the new stuff soon. I'm ordering a set of Savage saddlebag brackets because they'll support my bags better than the S40 version. I want to mount the battery in there and all the support on the S40 bags are up front... The Savage will cover SOME of the rear portion of the bag. We'll see! |
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Title: Re: My Build Thread Post by diamond jim on 04/30/09 at 19:04:40 Yeah, you'll need a washer on the rear left shock lower mounting bolt to take up the space where the belt guard mounted there. Otherwise it's simply remove bolts. There's a separate upper and lower guard. I got tired of the look of the pulley cover without the guard and reshaped the cover. http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021860.jpg Before the reshape (most of us know what it looks like): http://i255.photobucket.com/albums/hh128/russ_diamond_jim/1-24.jpg |
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Title: Re: My Build Thread Post by SimonTuffGuy on 05/01/09 at 04:26:05 Wow, that reshape makes it look really nice! I have to decide if I want to remove the guard or not... My girlfriend does ride with from time to time and I wouldn't want her to get caught up in the belt or anything. |
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Title: Re: My Build Thread Post by odvelasc on 05/01/09 at 05:51:22 DJ, how is your battery now held up? TG, what is the specs on the filter for your crankcase breather tube and the the cone filter. I may have to do the mod since my carb boot is not connecting to the airbox very well and am having ilde problems with my vm carb mods. I will check the clymer manual, but what is involved in removing the airbox? |
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Title: Re: My Build Thread Post by SimonTuffGuy on 05/01/09 at 06:21:29 The filter on the carb was the one that was being sold on the store here. I believe Lancer was the contact for them? I don't see them anymore, I believe they were trying to track down why the filters were tearing. No problems so far with mine, but I've probably put less than 100~ miles on the bike since mounting it. The crank case filter was just a cheapy filter that I picked up at Advance Auto (and I'm sure Pep Boys, A&A, AutoZone) would have them too. It was in the ricer section (neon lights, tire flys, etc) and ran $10. I got the blue one because it matched the bike... But I've seen red and black ones too. The box was a big PITA to remove... You'll have to pull the battery, remove the battery box. There are 3 total bolts holding the box in place and then you'll have to fanagle it out of the frame. I'm not sure how the CM carb mods change the carb itself... But, I removed my box with the carb still on the engine. If you remove the carb, it'd be a breeze to get out because you could twist it as you needed to pull out. There was a thread about this a few weeks ago that documented where the 3rd (and hardest to reach) bolt is located. It's up under the belt guard. I did mine with a small ratchet and it came right off. As for DJ's battery setup... I'll let him chime in too. But he's posted before that his right bag is essentially a hard bag, encased in a soft bag. He's got a thick piece of plastic against the back of the bag the holds the battery in place. The bag itself is zip tied to the bag supports that he used (which aren't Savage/S40 pieces). Maybe he can chime in again with one of his detailed drawings of how it looks. It's the same setup that I am going to try running... I'm getting a set of Savage saddlebag supports, because they come back furhter and will give the bag more support and room to zip to on... Where the S40 brackets are all towards the front of the bag. |
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Title: Re: My Build Thread Post by sakara on 05/01/09 at 07:53:43 Looks slick, DJ. |
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Title: Re: My Build Thread Post by diamond jim on 05/01/09 at 07:59:54 Simon got it right. I've got what is essentially a hard plastic case made up of individual sides assembled to make an internal box contoured to the slant shape of the inside of the bag. I added a verticle piece that divides the bottom 2/3rd of the bag into a two compartments with the part for the battery being larger and to the rear. I cut a piece of dense foam to sit in the battery compartment then cut out an area in the foam to slide the battery into. It fits ncice and snug. As far as bag mounting, I moved the rectifier to the bottom front of the rear fender. That left bolt holes on top of the rear fender where the rectifier normally goes. I forget the size (6mm I think) but I know they use a 10mm wrench. After moving the rectifier, I overlapped the bag yokes (straps) across the top of the rear fender and ran bolts through the yokes and into the threaded holes. I've got custom made bag supports so I have room underneath the bag yokes and fender to run the hidden battery cables. I'm pretty sure you could do this fine with the stock fender supports and OEM brackets but it might be a little tighter. |
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Title: Re: My Build Thread Post by odvelasc on 05/01/09 at 10:52:34 6F5551535268495A5A7B49453C0 wrote:
What is the diameter on the crank case filter? I dont want to buy the wrong filter. I can look up the diameter of the cone filter for the carb on the K&N website. Its outer diameter I believe I need. I might go with a foam Unifilter just for different looks. As for Jims battery. I remember that thread now. Very ingenius idea. |
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Title: Re: My Build Thread Post by diamond jim on 05/02/09 at 07:47:29 I first went with one of these: http://creeper.smugmug.com/photos/52666508-S-1.jpg The nipple fits loose inside the breather tube. I had put some electrical tape around the nipple to build it up to fit snug into the tube. The problem was that over time the little bit of oil that the air carries through the tube got to the tape and started loosening it up. I inspected it one day and found that the oil was causing the adhesive in the tape to fail and the tape started to work loose inside. I saw that it could potentially work loose and possibly start to block the little hole. I also got to thinking that that little hole itself my be too small and restrictive to allow for good flow. So I switched to one like Simon has only mine is chrome with white filter and made a chrome mount using an existing hole in the neck support for the mount bolt. http://i255.photobucket.com/albums/hh128/russ_diamond_jim/wkandn-1.jpg My tube fits snug inside the filter mouth sleeve instead of the other way around so there's no obstruction. I don't know how much of a difference it makes but it gives me peace of mind that the crankcase vent flow isn't impaired. |
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Title: Re: My Build Thread Post by tysonlguthrie on 05/07/09 at 15:02:47 Is there a reason you have the baffle way up there by the bend? |
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Title: Re: My Build Thread Post by diamond jim on 05/07/09 at 16:52:17 5558524E4F4D46545549534844210 wrote:
Yep. It sounds much better. The open pipe after the baffle allows the exhaust to develop a really nice deep sound. |
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Title: Re: My Build Thread Post by Wolf on 05/07/09 at 17:54:36 DJ, On the pulley cover (minus the belt guard) ... you need to add washers to fill the space(s) created when you remove the belt guard? I believe the upper bolt (of 3 bolts) is the culpret if I remember correctly. I didn't and it will rub the pulley. Also note the loose cables near the OPEN belt... these should be relocated or re-secured with zip ties. I haven't updated the pulley cover yet as I am still in "tearing down engine '96 mode" :o I am LEARNING (and buying MO tools and shop supplies) as I do his teardown before I attack my '99 engine ( eek tomorrow ) ;D Wolf :D |
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Title: Re: My Build Thread Post by diamond jim on 05/07/09 at 20:08:44 Are you asking me if you need to add a washer to the inside of the left shock lower mount bolt to take up the space where the upper belt guard had been mounted? Yes. Cables? Yeah, I had already moved mine when I removed the bike guts. |
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Title: Re: My Build Thread Post by SimonTuffGuy on 08/13/09 at 18:40:38 Let's see... Changes since last post: - Removed belt guard - Removed rear pegs (need to take off peg mounts yet) - Removed sissybar and rails My fender arrived today... The seat I ordered it on back order. Not sure if I'm going to check another source or not... Up next is to remove the stock fender and get the new fender mocked up. |
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