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Message started by arteacher on 01/14/12 at 13:56:30

Title: Chopper kit.
Post by arteacher on 01/14/12 at 13:56:30

I am considering a chopper kit-http://www.chopper-kit-usa.com/suzuki-LS650-Savage.htm, the 9 deg 4'' fork extension. This will have the effect of moving the front wheel ahead 5 3/4 " while keeping the bike level. This kit does not change the trail, only the rake.
What changes can I expect in the handling?

Title: Re: Chopper kit.
Post by built2last66 on 01/14/12 at 17:27:37

Um, just remember that rake extension choppers are made for going in a straight line, really well... that's what they're made for... highways and such.. here's a link Verslagen1 posted awhile ago about fork rakes and suspension that you may have read that should help answer:

http://www.carbibles.com/suspension_bible_bikes.html


Title: Re: Chopper kit.
Post by built2last66 on 01/14/12 at 18:25:07

Oh yeah, if you get that kit you have to get this shirt to wear when ya ride 'er down the block:

http://ecx.images-amazon.com/images/I/41vk7h5hipL.jpg

[smiley=2vrolijk_08.gif]

Title: Re: Chopper kit.
Post by SuperSavage on 01/14/12 at 19:35:09

I'm not a chopper guy, but that is a very nice conversion.  I like that more than the RYCA and Bobber look. Not many S40 Choppers running around. It looks very lean and clean. Don't expect crisp handling and turning, but you'll be turning heads a plenty.

                                                   JohnnyCat

Title: Re: Chopper kit.
Post by Bubba on 01/17/12 at 07:11:52

wow, you could buy another bike for the price of that kit!

Title: Re: Chopper kit.
Post by arteacher on 01/17/12 at 08:11:21


221502020151505853600 wrote:
wow, you could buy another bike for the price of that kit!

Yea, I know. The question is- do I WANT another bike? :-/

Title: Re: Chopper kit.
Post by built2last66 on 01/17/12 at 08:40:25

It's kinda cool.. if you have $2k layin around I'd say go for it if you like it...

Title: Re: Chopper kit.
Post by spacepirates on 01/17/12 at 09:28:30


343F3F363A35342E2F5B0 wrote:
[quote author=221502020151505853600 link=1326578190/0#4 date=1326813112]wow, you could buy another bike for the price of that kit!

Yea, I know. The question is- do I WANT another bike? :-/[/quote]


yes. always yes.

got to have one to ride and one to wrench. i had the savage down for a month in prime ride time and it was horrible. never again. have to have redundant motorcycles.

i've picked up the bad habit of looking at what bikes are on craigslist for under 1k. every once in a while i'll see something for $300 or so as a fixer upper and i think how lovely it would be for another bike. so much fun...

Title: Re: Chopper kit.
Post by justin_o_guy2 on 01/17/12 at 09:41:53

I saw a guy with a neat lookin chopper at Sams. He was riding with a guy who had a bagger HD. They went to leave. The guy on the bagger stuck it in gear & rolled it out of the last parking space in a Uturn to head on out. The guy on the chopper did the same. Had enough room for me to turn the Vibe around in nearly, & he had to stop & back up & try again. Downright dangerous for a town bike. In traffic, being able to stop & turn is part of staying alive, getting killed on a cool looking bike is still being dead. Ill stick with maneuverability.,
Its a cool looking thing, tho, Ill give ya that. I think Bobbers look cool, but no fender? Not safe..

Title: Re: Chopper kit.
Post by built2last66 on 01/17/12 at 09:56:52

Not having a fender is perfectly safe if you're wearing a welders mask without the tinted glass...

Title: Re: Chopper kit.
Post by Arnold on 01/17/12 at 12:04:49

Been riding without front fenders for over a year now, no problem.

Title: Re: Chopper kit.
Post by arteacher on 01/17/12 at 12:27:48


302F292E33340535053D2F23685A0 wrote:
I saw a guy with a neat lookin chopper at Sams. He was riding with a guy who had a bagger HD. They went to leave. The guy on the bagger stuck it in gear & rolled it out of the last parking space in a Uturn to head on out. The guy on the chopper did the same. Had enough room for me to turn the Vibe around in nearly, & he had to stop & back up & try again. Downright dangerous for a town bike. In traffic, being able to stop & turn is part of staying alive, getting killed on a cool looking bike is still being dead. Ill stick with maneuverability.,
Its a cool looking thing, tho, Ill give ya that. I think Bobbers look cool, but no fender? Not safe..

JoG, here is another link which explains the geometry of their kit. They claim that because the kit does not change the trail at all, handling isn't affected. My gut felling is that some aspect of handlig would change, but I don't understand how.
http://www.chopper-kit-usa.com/index.htm

Title: Re: Chopper kit.
Post by Arnold on 01/17/12 at 12:35:20

Just say goodbye to turning radius.

Title: Re: Chopper kit.
Post by built2last66 on 01/17/12 at 18:48:13

That's such a short rake that I doubt it's gonna change sharp turning too much, but that's a pretty penny for just a tree mod so I hope you LOVE it.. maybe they have those springer air ride front ends out for the savage yet?

Title: Re: Chopper kit.
Post by arteacher on 01/18/12 at 14:59:24

Now that I think of it I remember someone here had a kit. It was on a white S40 I think. Anyone remember who it is?

Title: Re: Chopper kit.
Post by Demin on 01/18/12 at 16:00:54

Yep...JRM8486
From Florida.

Title: Re: Chopper kit.
Post by arteacher on 01/21/12 at 03:39:34

I sent him a PM but no reply yet. I talked to a Harley guy who has ridden several different bikes, some with fork extensions-rake mods, and he suggested that such a gentle extension will not cause very much change in handling, a minimal loss of turning radius, and an improved ride, because of the longer wheelbase.
So I think I'm going to go for it. 8-)

Title: Re: Chopper kit.
Post by built2last66 on 01/21/12 at 05:30:05

I didn't think it would change too much being a short rake, good luck with it.

Title: Re: Chopper kit.
Post by arteacher on 02/02/12 at 13:36:14

Canadian currency went above US (slightly) which pushed me over the edge. Dropped the dime today.
BTW, by the time I pay 13% sales tax and duty the total cost with shipping will be around $2700. I thought long and hard about this, as I will be getting a substantial tax refund, and could afford to pay cash for a new Triumph America.
I decided that I like Lil Suzy ( from "Wake up lil suzie" by the Everly Brothers) too much, so I will buy her the stuff to look real sexy.

Title: Re: Chopper kit.
Post by skeebo on 02/02/12 at 17:44:57


2633282B2B22332235470 wrote:
Been riding without front fenders for over a year now, no problem.

No fender No problems
http://a1.ec-images.myspacecdn.com/images02/144/d114595b98fa47179f6054bb029dfa28/m.jpg

Title: Re: Chopper kit.
Post by arteacher on 02/18/12 at 13:28:18

An issue has arisen. The width of the kit is greater than stock, so the SuperBrace will have to go. Oh, well. :(

Title: Re: Chopper kit.
Post by Savage_Rob on 02/18/12 at 22:33:27


4B404049454A4B5150240 wrote:
An issue has arisen. The width of the kit is greater than stock, so the SuperBrace will have to go. Oh, well. :(

You might try sending the measurements to TKat if you want another brace.  I've been away for a while but I assume he's still making them.

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 05:15:48

Thanks- I had thought of that. When I get it on and ride it for a bit, I'll make that decision.

Title: Re: Chopper kit.
Post by palehorseman on 02/19/12 at 09:22:30

Ive had plenty of choppers...
The real question you gotta ask is why you want one.
Theyre ALL only good for two things:
Short straight line runs
N Photo shoots
Due to a lack of experience and a desire to put fashion ahead of function I tried to use them for weekend ridealongs and daily drivers.
Forget it!
Be comfortable n functional n ride alot.
or be fashional n flashy n look at pictures of your garage art.
Just my two cents.

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 09:33:33

"The real question you gotta ask is why you want one.
Theyre ALL only good for two things:
Short straight line runs
N Photo shoots"
My reason for doing this is to get 6" more wheelbase. My reason for wanting that is better stability on the highway, and a better ride.
It will not change the appearance that much.

Title: Re: Chopper kit.
Post by palehorseman on 02/19/12 at 09:52:57

Oh it greatly improves high way cruising especially on this frame because it elivates the factory front seat into a better position... so does lowering the rear. But at highway speed the true trail...which is what extended forks actually change... is too little to notice. You get a degree or two of rake thereby extending the stance. But pulling onto or off on the exit ramp feels like crap. You cant corner or negotiate turns once u get off the highway. And parking in a tight spot requires effort.
look...you asked for input. Im sorry if you dont like mine. Im trying to save you problems. Call me after riding a chopper for a few years n we'll see if your taking the same stance. Im not naysaying anything...im being brutally honest. If you want one of those two things go for it. But don't kid yourself. Do a seat mod and be comfortable in any practicle situation

" i built it for dramatic effect... and we actually did the ride...but man did it handle like nuts" quote in reference to the movie that started the fad: Henry Fonda... easyrider

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 10:31:14


6E6F7C77786D766B190 wrote:
Oh it greatly improves high way cruising especially on this frame because it elivates the factory front seat into a better position... so does lowering the rear. But at highway speed the true trail...which is what extended forks actually change... is too little to notice. You get a degree or two of rake thereby extending the stance. But pulling onto or off on the exit ramp feels like crap. You cant corner or negotiate turns once u get off the highway. And parking in a tight spot requires effort.
look...you asked for input. Im sorry if you dont like mine. Im trying to save you problems. Call me after riding a chopper for a few years n we'll see if your taking the same stance. Im not naysaying anything...im being brutally honest. If you want one of those two things go for it. But don't kid yourself. Do a seat mod and be comfortable in any practicle situation

" i built it for dramatic effect... and we actually did the ride...but man did it handle like nuts" quote in reference to the movie that started the fad: Henry Fonda... easyrider

It's not that I don't like your input, it's just that you haven't researched this kit like I have. I am not just throwing on longer forks here. It's TUV certified, and they are very particular about what they certify.
This kit does not change the trail at all. I am getting the 9 deg kit with 4" longer forks, which will keep the bike level, extending the wheel about 6". The only downside will be a slightly increased turning radius, and the fact that I will have to buy a larger cover. ;D
And of course a stock frame with 12" overstock forks will "handle like nuts".

Title: Re: Chopper kit.
Post by palehorseman on 02/19/12 at 10:49:49

Unless triganomitry has changed it must. Descrbe trail as you understand it so i can be better informed. First off triple tree rake is the worst way to go to achieve additional rake. Modifying the neck is the only good way to build a raked ou bike. But there are few practicle reasons. Rake is necessary for drag bikes. Drag bars are necessary for drag bikes. But no one uses positive raked trees for drag bikes. What does that say? The only reason trees with rake are practicle is to right trail...but those are in essence opposite...they are longer from pivot on the top instead of the bottom.
You can Lower the rear to get more rake. You can raise the seat at the mounts to get a better seat position. But im telling you... you cant extend forks and add positive rake in trees and not effect trail. Thats just not possible. Its like raising a vehicle and saying it doesnt lower the center of gravity... it cant be done. Google real reviews on the subject outside of this forum. I hope i was helpful and didnt come off wrong. If i can help let me know. Ive made my own costly mistakes n am trying to save you the same. Who do u think is telling the truth... the guy with nothing to gain or the one trying to sell you overpriced parts? Best of luck. :)

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 11:23:33

OK. I am not a math guy so my description might not be the easiest to follow, but here goes:
If you draw an imaginary line along the steering axis to the ground, and another line vertically down from the center of the wheel, the difference is the trail.
The kit adds the nine degrees to the steering axis, not the trees, so the trail stays the same, as long as you extend the forks the proper amount.

Title: Re: Chopper kit.
Post by palehorseman on 02/19/12 at 12:02:51

You get it. Thats basically trail. Now rough draw what your saying n see if what they say makes any sence. Hope you get what your after.

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 12:23:43

I drew it out and the trail is almost exactly the same. ;)

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 15:33:09

You are not paying attention. The trees are NOT raked. They use an adapter to change the steering axis. It is like changing the rake by cutting and welding the neck, but without cutting and welding. The adapter extends the bottom of the neck the required amount, changing the steering axis angle. you get the same trail whether you use their 9 deg kit or their 18 deg kit.
I already told you why I want it- in a nutshell I want a longer bike for the ride without the weight.
I don't need anyone's justification to buy it- if you had read the whole topic you would know I already did.
And as far as looks go, I dislike the looks of all the 14 degree LS650's they have pics of on the site. Unfortunately they don't have a pic of one with a 9 degree kit-but they will soon. ;)
What I am going to wind up with is a bike that is 6" longer, slightly heavier (the trees are steel, not aluminum) with a better ride, according to a guy who put an 14 degree kit on an intruder, with "different, but not worse" low speed steering, and much more stable at high speeds.

Title: Re: Chopper kit.
Post by palehorseman on 02/19/12 at 16:31:11

Best luck with that.

Title: Re: Chopper kit.
Post by arteacher on 02/19/12 at 16:55:29

Thanks. And why did you delete your previous post?

Title: Re: Chopper kit.
Post by bluesrockdoc on 02/20/12 at 06:57:56

Git' ta wrenchin'.... I wanna see this!   :)

Title: Re: Chopper kit.
Post by arteacher on 02/20/12 at 08:22:26

I should get the kit early in March, and will have to wait for decent weather (no garage) to install it, but I will post pics as soon as it's done.

Title: Re: Chopper kit.
Post by thehoghunter on 02/21/12 at 13:15:56

If this is the same kit I put on, you are going to love it.  I got mine back in 2003 from Seeger Cycles (I think JRM8486 From Florida also got his from Seeger Cycles (Seeger doesn't sell them for the Savage/S40 anymore).  The kits were from a company in Germany - and for all the folks that will tell you it's messed up,
1. German engineering
2.  the German government's TUV has a great record when approving products for the road - they don't let junk onto the market (versus our government that looks at stuff after people have died) - the kit was approved by TUV, which means it had to go through a 50,000 mile road test before it could be certified for the Autobahn.

http://p1.bikepics.com/2004%5C12%5C02%5Cbikepics-252759-full.jpg
http://www.bikepics.com/members/thehoghunter/
I guess the 'discussion' I had on here was deleted/lost since it was back in 2003.  

The wider turn radius isn't that bad...I could still make a U-turn (once I got use to it) with no extra room needed...and it handles just fine in town, it actually feels like I thought a motorcycle should feel versus stock.  Riding my wife's Savage (stock) feels weird after being on mine.

Title: Re: Chopper kit.
Post by SuperSavage on 02/21/12 at 15:05:17

HogHunter, that kit looks great on the savage - It looks much better than stock. artteacher is gonna love it. I bet you get a lot of attention riding that hog.

Title: Re: Chopper kit.
Post by SuperSavage on 02/21/12 at 15:08:46

That dual headlight and seat looks great as well. Bravo, nice job

Title: Re: Chopper kit.
Post by arteacher on 02/21/12 at 17:07:37

It looks like a 14 Deg kit?
Thanks for the support- i kinda felt that I was all alone out on a limb, dropping that kind of scratch with all the nay-sayers telling me I was crazy. :)
Like those colours too.

Title: Re: Chopper kit.
Post by thehoghunter on 02/22/12 at 09:31:36

Info sent to me back when Seeger was selling it for the Savage:


Quote:
To give you a little more info on the kits, they were designed, developed and patented by FS Chopper in Germany over 20 years ago. To be able to sell the product it had to have approval by the TUV. In fact each time they make a kit for a new motorcycle it has to go back through the testing process, so that means each kit has been tested on the particular bike. One part of the test is actual road test, the motorcycle must ride and perform like the stock motorcycle (there is some consideration for a bit more steering effort at low speed). The bike is riding up to the bikes top speed and must be as stable as the stock bike. The testing also involves taking a stock motorcycle equipped with the kit and putting it into a test stand (a type of road simulator). This test stand will shake, bounce and vibrate the motorcycle to simulate 50,000 km (about 31,000 miles) of actual riding. Then all parts are disassembled and inspected. If the parts show any stress cracks or any type of failure the kit can not pass the test. Going one step further the also inspect the original motorcycle frame to verify no stress shows on the neck.

Another company in Germany has manufacturing rights from FS Chopper they are called AME you can see there website at  http://www.ame-chopper.de/
They offer a chopper kit based on the same design.

Title: Re: Chopper kit.
Post by x1karr0usx on 02/22/12 at 12:54:50

i would imagine it is a cheaper job just to take it to a good shop and get them to add some rake to the neck.. seems like a lot of money for a bolt-on kit. but, i guess if it is worth the cash for your bike, do it up!

Title: Re: Chopper kit.
Post by thumperclone on 02/22/12 at 14:49:49

i just went with ED L forward controlls and drivers back rest and sheep skin seat cover and back rest cover..
like in a easy chair..

a true chopper is when you chop a section outa the frame

this ol mans back luvs my mods.. nice and comfy,
when the wifey is on the rear i remove the drivers br she is endowed enuf that its acutally more comfey if you get my drift..

Title: Re: Chopper kit.
Post by arteacher on 03/23/12 at 13:10:37

Fedx delivered 2 of the three boxes today. The quality of the kit is stellar.
They use Yammy virago fork tubes , which happen to be 4" longer than our stock tubes, with thicker walls.
So I get better quality tubes, new springs and dampers as well. I didn't expect these upgrades. :)

Title: Re: Chopper kit.
Post by greenmonster on 03/23/12 at 13:13:50

Art, Looking forward to seeing some pic's when you have them!

Thumper, do you have any pic's of your driver's sissybar? I've been thinking of doing that to mine but wasn't sure if it would look right.

Title: Re: Chopper kit.
Post by verslagen1 on 03/23/12 at 14:19:51


2922222B2728293332460 wrote:
Fedx delivered 2 of the three boxes today. The quality of the kit is stellar.
They use Yammy virago fork tubes , which happen to be 4" longer than our stock tubes, with thicker walls.
So I get better quality tubes, new springs and dampers as well. I didn't expect these upgrades. :)


Same diameter fork tube?

Title: Re: Chopper kit.
Post by arteacher on 03/23/12 at 16:46:15

I haven't checked yet but I would imagine they are, unless I get the whole fork assembly in the third box on Monday, :-?

Title: Re: Chopper kit.
Post by jrm8486 FSO X2 on 03/28/12 at 05:02:26

Sorry, loved the kit would do it again. might buy a savage for the wife soon.  
http://p1.bikepics.com/2007/12/31/bikepics-1133086-800.jpg

Title: Re: Chopper kit.
Post by Demin on 03/28/12 at 05:32:32

I've seen this kit around for a long time.I love the kit,I usually just don't have that much money to spend at one time,lol.People don't understand how it works...so it's bad.
As for it not being a "real" chopper.(You could start a whole thread on what a "real" chopper is).I kind of like this.That way if you ever want to put the bike back to stock for whatever reason you can.When I build a bike to sell,I usually just put struts in place of the shocks,that way if the person buying it wants shocks...Bam,10 minutes you have suspension again.
::)

Title: Re: Chopper kit.
Post by SuperSavage on 03/28/12 at 21:21:33

JRM, that bike is sweeeet! It looks like the savage was made for a "Captain America" look. Very nice bike.

Title: Re: Chopper kit.
Post by Arnold on 03/29/12 at 11:22:25

With fork kits like these you could really move the controls way forward.

Title: Re: Chopper kit.
Post by arteacher on 04/07/12 at 05:07:08

Bit of an update and a question:
There have been two glitches with the install. The kit instructions tell you to use the original oil plugs in the sliders, but they wouldn't fit. Had to order the right ones from Yamaha, as they are stock fork tubes (made by Frank's Forks) from a '95 Verago 1100. Due to Easter, I won't get them till Thursday.
The top tree hits the tank. Chopper Kit USA is making some larger diameter stops to rectify the problem.
The question is: The instructions tell you to use the stock amount of fork oil, but he Yamaha forks have a narrower inside diameter, and Yamaha spec is 372cc vs Suzuki spec at 447cc. I am inclined to follow the Yamaha spec, but would like other opinions.
Oh well, it will give me time to polish the sliders and signal mounts.
BTW the customer service I am receiving from Greg at Chopper Kits is phenomenal. He gives you his personal cell #, answers e-mails within hours. He is refunding the cost of the oil plugs + some for my trouble.
Can't beat that! :)

Title: Re: Chopper kit.
Post by arteacher on 04/15/12 at 15:07:56

Yet another update- still waiting for parts. The Yamy oil plugs for the fork tubes are back ordered and on there way (I hope) from Japan. The new fork stops are on there way from Chopper Kits.
I also have two other issues to deal with: I have to get the front fender painted (or paint it myself) as the Superbrace did some paint damage because I installed it touching the fender. Also the Suzuki windshield will no longer fit as it is now tilted back an additional 9 deg and makes contact with the master cylinder. I have pretty much decided on the Slip Streamer Billet 18", http://www.slipstreamer.com/Product/Cruisers/cruisers.html pending answers to some questions put to the manufacturer. I had thought about not having a windshield, but I really hate combing bugs out of the beard. ;D
Oh well, it gave me the time to clean up the corrosion on the sliders and signal light mounts, and install Versy's pins in the seat, and some other piddly stuff that needed doing. And it's been raining or cold here quite a bit anyway.

Title: Re: Chopper kit.
Post by arteacher on 04/18/12 at 17:38:13

Well, it's all together now. Just waiting for the new fork stops to arrive, and bleed the brake. Then I will take it for a test drive, clean it up, and post some pics.
I must admit, I was very apprehensive about dropping that kind of coin on something without even seeing a picture of it (all the pics on their website are of 14 deg kits, not the 9 deg I bought.) The 9 deg looks much better than the 14 IMHO. The bike is too small to have the front wheel extended more than 6" or so. You can do the math and play in photo shop all you want but until it is sitting there in front of you you only have a general idea of what it's going to look like.
There are some hidden expenses as well: The stock windshield no longer fits, and I have to get a larger cover.

Title: Re: Chopper kit.
Post by arteacher on 04/25/12 at 03:56:57

Posted pics in Cafe.

Title: Re: Chopper kit.
Post by srinath on 09/20/12 at 09:52:36

Ooooo this was the thread I should have been looking for.

http://picasaweb.google.com/srinath.the.man/SavageChopperBuild#53768675803138...

That is my chopper built ~3 years ago.

Ooooo this was the thread I should have been looking for.

This was my observation after doing the chopper mod the way I did.

The front wheel is 21" aluminum. So @ the same road speed, that wheel spins about 25% less. It also is about 1/2 the weight of the steel wheel. Therefore with the rotational kinetic energy only takes into account the effort required to turn its direction is of the order of 50% less.
Now the offset in the savage triples are 2.5". The custom triples I made didn't touch that, else I'd clobber the tank ... so 2.5 it was. However the wheel has an offset axle. I flipped the legs left to right and ended up with 1.5" taken out of the offset effectively. The bike was a lot lighter to steer as a result. Its a demostrable effect I will gladly show anyone who wants to stop by my house in charlotte NC. I have a maxim FE in a savage I should finish out in the next few weeks.

Here is the other cool factors with this mod.

The stock FE out of most 80's dirt bikes - DR250, 350, 650, KX125, 250, 500, rm 125-500, and more, I just tried these, typically yamaha used 28X28 mm stems and honda used 26X30 and suzuki and kawi used 25X30. So kawi and suzuki FE's are drop in to the savage which uses 25X30. 26X30 is useable too, just get the complete upper bearing with it - you have to pull the outer race from the frame - usually damaging it. So get a new one ... I did for that bike.

So a whole FE 9"-11" longer just drops in ... triples and all. So what's the problem ... yea the tank. These FE's all have 1"-1.5" offset, we need 2.5 minimum.
So you make upper triples ... Or cut and weld the frame.

Do triples if you have a good machinist - Make them to be spaced as in the triple you are using the offset needed to clear the tank on the savage and the extra rake you need to get it looking right. I'd do no less than 7 degrees, no more than 12. But to each his own. That bike was a 9.
What you have to do is to cut a wedge with the rake you want out of metal or even wood. That will be used to block up the triples in the mill. I used 1" plate for the top and 1.25 for the bottom 6061 aluminum. The distance from upper to lower triple i na savage is ~6.3" if I recall. Measure it. You need it for your calculations.
Now in the Upper triple is 2.5 from the center of the stem to the forks, lower triple is 2.5"+ [6.3" X cosine (rake ange)].
Center punch those spots in the aluminum plate and take to the machinist. Done in under 1 hr.

Now the weldup method - I have only theorised this not done 1 myself.
Find a welder who has experience chopping a bike.
Get thin walled steel channel section of 6" or 3 2"X2" box section square tubing. Weld it to make a 2"X6" section and cut 1 end straight and the other mitered to your rake. Put it in and weld it up. Why the 2" stretch on top - the dirt bike FE you would use has a 1" offset or so ... without 2" on top, you'd clobber the tank ...
After that its simply bolting everything together.

In a way that dirt bike FE turned backwards makes all the difference for handling so I will just say leaveyourself that option if you do this.

The frame or triple clamp job should cost you under 400 labor and materials. The forks off a dirt bike - whatever your local junkyard charges for them. I paid around 20 for the few FE's I got ... 3-4 ... but they were all missing parts. I dont see a complete one going for over 100. $500 and other misc like bearings tires, tubes etc cos no dirt bike gonna have street tires on it ... so 600-700 depending ... for one delicious little very very easy and streetableas well as reliable and freaking one of a kind chopper ...

Cool.
Srinath.

Title: Re: Chopper kit.
Post by arteacher on 09/20/12 at 14:31:37

Sorry, that link does not work for me.

Title: Re: Chopper kit.
Post by ToesNose on 09/21/12 at 04:37:38


464D4D444847465C5D290 wrote:
Sorry, that link does not work for me.



+1    :-?

Title: Re: Chopper kit.
Post by srinath on 09/21/12 at 08:07:40

I am @ work, and nothing works from here ... so I have to get back tonight ... sorry.
Cool.
Srinath.

Title: Re: Chopper kit.
Post by srinath on 09/23/12 at 05:59:47

https://picasaweb.google.com/srinath.the.man/SavageChopperBuild?authkey=Gv1sRgCJ-TlundyLiSngE

Hope this works. Cut and paste the entire link.

Cool.
Srinath.

Title: Re: Chopper kit.
Post by Cavi Mike on 09/23/12 at 16:05:21

Link still doesn't work. Needs url brackets. The forum is breaking up the link.

https://picasaweb.google.com/srinath.the.man/SavageChopperBuild?authkey=Gv1sRgCJ-TlundyLiSngE

Title: Re: Chopper kit.
Post by Greg on 09/23/12 at 16:15:18


3A3B2027283D21490 wrote:
The front wheel is 21" aluminum.

Would you share details about the wheel? I have been wanting to go to a 21".

Title: Re: Chopper kit.
Post by srinath on 09/23/12 at 18:18:20

I used a entire Kx250 1986 Front end, that 21" was what it had. putting a 21" in the stock legs may be much harder.
I fabbed up triples and that bolt spacer as an additional insurance type thing. 3 parts was all I had to make.
I had the top risers drilled to fit harley risers, 3.5" spacing.
Anyway 21" front wheel is really what the savage should have had.
Cool.
Srinath.

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