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Message started by BurnPgh on 01/31/10 at 21:31:01

Title: special tools
Post by BurnPgh on 01/31/10 at 21:31:01

about to finally tear the savage down for a sup up. My buddy has almost finished his schooling as a machinist and he and his instructor have agreed to do some of the work im wanting done. My buddy has read the clymers to farmiliarize himself with exactly what I want done. He didn't express any concern on this score but im curious...does anyone know if there are considerable differences in suzuki's special tools (reamers, handles, etc) to differentiate them from standard type reamers that would be generally used in machining?

Im hoping no, because I cant for the life of me find a source for the suzuki tools though I have been looking just in case.

Title: Re: special tools
Post by verslagen1 on 01/31/10 at 21:39:17

what sup doc?

had to ask

Title: Re: special tools
Post by Oldfeller on 01/31/10 at 21:51:28

Only specialty tool that seems to be "lacking" or hard to get for our bike is the rotor puller.

Title: Re: special tools
Post by BurnPgh on 01/31/10 at 23:18:36

564552534C4147454E11200 wrote:

what sup doc?

had to ask

Not much. Being rushed, broke, and half @$$ed about it the first time has lead to the new improved version of the same question i had 6 months ago.
Now about them tools OF. Im looking for the suzuki brand since thats the only PN I have for such items. Have you got other PNs/sources or is that your clever way of saying that I need not worry about differences between the suzuki vs general machining reamers etc

Title: Re: special tools
Post by justin_o_guy2 on 02/01/10 at 01:02:21

My buddy has read the clymers to farmiliarize himself with exactly what I want done.

Unless someone is well farmiliarized with the equipment, it is hard to properly shade tree mechanic on it.

Title: Re: special tools
Post by BurnPgh on 02/01/10 at 02:07:47

he's about 2 weeks away from getting whatever certifications it is he needs to be a machinist. He knows his stuff and his instructor is allowing him and I to use the school shop for this. If there's any hitches the auto tech class which is also a few weeks away from getting certifications is just down the hall. Seems a few people take thier cars to the school and a lot of the finer bits or engine work get sent to the machine shop anyway so might aswell cut out the middle man.

Title: Re: special tools
Post by smokin_blue on 02/01/10 at 03:13:17

The suzuki tools are pretty straight forward. Most should be able to be machined by a machinist. The key will be matching the metric pitch with usually larger than standard diameters which will require setting up the metric change gears on the lathe to turn the threads (rather than just buying a tap). Most specialty tools can be made. I have done many for my suzukis over the years. One key difference will be whether there is a need to for any hardened surfaces. Many times the suzuki tools might be case hardened but that is so they stand up to the repetitive use in a dealership shop. A few might require case or through hardening just to have the physical strength and hardness to work but I have found that is somewhat limited and can be designed around using hardened fasteners or pins in appropriate places.

Title: Re: special tools
Post by BurnPgh on 02/01/10 at 12:52:25

120C0E0A080F3E030D1404610 wrote:

What I mean to say is...do I need to use the suzuki special tools (reamers specifically) or are they just branded versions of general machining tools? If I need to use the suzuki tools where in the world do I find them?

The shop has metric reamers and my friend didn't seem at all concerned about doing what Im asking.

edit - Been looking all day online for tools. I was able to find the 12.3mm suzuki reamer and an aftermarket 7mm reamer thats intended to be used in place of the suzuki 7mm reamer. I cannot find the handle for the reamers though. It seems the handle is discontinued/unavailable/obsolete (depending which site i looked on). Also found the guide installer and attachment. I have yet to find the guide remover although I have found some inches, but I dont know what size I need as im going just by the PNs in the clymers. In any case my question still stands....is there something special about the design of the suzuki reamers that makes it necessary to use them as opposed to the reamers at the machine shop?

Title: Re: special tools
Post by smokin_blue on 02/01/10 at 18:14:00

If you know the size of the reamer it really shouldn't matter whether it is a suzuki brand or other.

If you want 7mm chucking reamers take a look at
www.mscdirect.com

and look under reamers and then find 7mm under the size tab.

good luck!

Title: Re: special tools
Post by BurnPgh on 02/08/10 at 21:09:18

I HAD found most of what I was looking for, and ordered the parts, only to find that they are all discontinued. I suspect the Pns are just different now. Does anyone have a Suzuki Service Manual or a post-04 clymers? Looking for more up-to-date PNs.

Title: Re: special tools
Post by verslagen1 on 02/08/10 at 21:20:17

What you order and where?

Where ever you ordered, the guy has the IQ of a worm.

Title: Re: special tools
Post by BurnPgh on 02/08/10 at 21:52:32

speedsupplies.com and another site whose name escapes me at the moment. speedsupplies had (supposedly) the fork tool and handle (the broomstick trick doesnt work well for me) aswell as valve guide installer handle and attachment. The other site had the reamers but no handles. Funny thing is, when i typed in the clymers PN it provided me with updated PNs which i then ordered...4 days later even the "updated" PNs are discontinued on both sites. Bore-tech.com has the fork tool but not the handle, though i did send them a message seeing if they could come by the other tools. The closest dealership sucks but i may just give them a call and let them do the hunting. I did find "the pit stop" which has all sorts of suzuki special tools, but only for their cars. Nothing moto specific.
On the brighter side, my wiseco 95mm piston came today...which is amazing considering the road conditions.

Title: Re: special tools
Post by T Mack 1 - FSO on 02/10/10 at 10:23:35

I bought my 01' Savage with the engine in pieces. I can verify Oldfeller's comment, the flywheel puller (50mm thingy) is the only special tool that is needed.

Just need a good selection of metric tools otherwise.

Title: Re: special tools
Post by BurnPgh on 02/10/10 at 14:06:42

what should i use for the forks then? Ive tried the broomstick trick and ruined 3 broomsticks. The bottom bolt on the forks is to freakin tight that the carved broomstick just strips trying to hold it in place while loosening the bolt. If i took them to the nearest dealership they;d probably charge me for a full fork rebuild even though I only need two bolts loosened.

Title: Re: special tools
Post by verslagen1 on 02/10/10 at 14:47:33

Sorry, took me awhile to remember.

There was a guy here who welded a nut on the end of a pipe that fit inside of the tube. I'll have a look when I get home if some emergency does crop up again.

Title: Re: special tools
Post by verslagen1 on 02/10/10 at 21:19:15

A 15/16" nut fits in there tightly or 23.5mm

Buy yourself 2, a long enough bolt and you got yourself a special tool.

Title: Re: special tools
Post by BurnPgh on 02/10/10 at 22:59:19

tank ju berry mush.