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General Category >> Rubber Side Down! >> Initial Mods to S40
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Message started by ihasabike on 05/08/14 at 05:49:17

Title: Initial Mods to S40
Post by ihasabike on 05/08/14 at 05:49:17

Hi! I got a used S40 this past weekend. I already have a Gixxer 1K, but it is not comfortable for me or my husband. I find driving my husband's shadow saber to be more comfortable, but it is still too big for me, so I was looking for a light cruiser.

The S40 I got is a 2012 that had 1695 miles on it when I bought it. The previous owner had put an odometer, aftermarket filter, and obnoxiously loud aftermarket exhaust on it. I bought it from a dealer.

The S40 worked great for a while, but by the end of the first day, it was stalling when I stopped. Then it would stall when I slowed down. Then it wouldn't start easily. I started researching and came across this site, including the advice on the petcock, adjuster, and raising the front of the seat 1-2 inches.

In testing the petcock, I found running it in prime yielded no improvement, so I took it back to the dealer and they figured out that the aftermarket oil bath filter was dry. It was so dry that it was white instead of red. They fixed it for free and also put the stock exhaust back on for me. Now it runs great and purrs like a kitten. :-)

I had already ordered the raptor 660 petcock, and I have it now. I will get it installed next time I take it in for service. I talked to the dealer about it and they agreed it would be helpful, especially because it would permit me to switch to off and run the gas out of the carb when storing for the winter, and thus avoid needing maintenance when I start using it again in the spring. They didn't seem to be aware of a petcock failure issue though.

Meanwhile, I have ordered some bags, an engine guard, and foot pegs. I'm having an issue with the bags not shipping, and the reply from support at viking bags support explaining, in broken English, that they have a shipping delay is attached. Has anyone dealt with Viking Bags? Should I be concerned about this company?

Finally, I have searched for, but I have not been able to locate, any threads about how to raise the front of the seat 1-2 inches. Can anyone link some threads with instructions, pics, or vids?

Having scoured many threads here, I know how helpful and friendly people are here, so I'll say "Thanks" in advance. :D

Title: Re: Initial Mods to S40
Post by old_rider on 05/08/14 at 06:57:40

From the Viking site at the top there is a number to call or a direct chat.

http://www.vikingbags.com/

You have picked a great bike to ride.....most of us have or have had other bikes and ended up lovin' these little beasties.

Get you a good tool set and save some maintenance money! The Savage/S40 is an easy bike to learn how to wrench on, and with the guidance on this site, easy to fix!

Forgot to add the seat link

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1109035237

The Technical/Documents section has a Table of contents with links area that covers about everything you will ever want to know about these bikes...

Title: Re: Initial Mods to S40
Post by WD on 05/08/14 at 08:05:47

Suzuki has consistently refused to recognize the issues with the factory petcock, which have gotten worse. They used to last a few years, now, many are failing in a few months. Outsourced petcock production to a Chinese facility.

Raising the seat front can help, or equate to nothing. Won't know until you try, should run less than $10 even with stainless steel bolts.

You can get a more than adequate toolkit for these bikes for less than $25 out the door. Throw away the stock belt tension gauge, keep the sparkplug, hex key and axle wrenches (with extension handle), add a few combination wrenches in 8, 10, 12 and 14mm. Add a 1/4"drive ratchet and extension with sockets in those same sizes. Buy a tool roll to hang under your headlight, and keep your tools, spare bulbs (in old pill bottles or 35mm film canisters), and a 5 pack of 20A yellow blade fuses in it. The battery box end "tool box" is a bad location for tools.

The Savage is a neat little machine, a cross of a pre-1970s British single (including oil leaks for nostalgia) and 1970s J.A. Pan Inc electrical parts, but with modern fuses.

Go ahead and order your new tires now. Shinko is more than adequate for a Savage, has been around for decades as Maxxis and ChengShin... The stock IRC tires are atrocious. IRC makes some extremely good tires, but not the series fitted to our bikes at the factory. The Shinko 777 rear whitewall is good for up to 15K miles on stronger/heavier machines with better brakes, and is also available as a blackwall.

Bookmark Motorcycle Superstore. Bookmark Lowbrow Customs. Bookmark Bike Bandit for its exploded view parts diagrams.

You can turn a Savage/S40 into anything stylewise. Do a Google image search, sit back with your cold beverage of choice, and spend some time drooling. Especially over the European customs. I happen to have a pair of them, one looks like an old outlaw hotrod, the other an old police bike...

Have fun, welcome to the family.

http://i1277.photobucket.com/albums/y490/mphsgal/LISA-HP/Photos/Savage/bigbags_zps78b2dfad.jpg

http://i1277.photobucket.com/albums/y490/mphsgal/Jeffs%20pix/Sam/sam_left_zps56cde95d.jpg

Pics or it didn't happen... ;) Seriously, show off your new ride. We like bike pics.

Title: Re: Initial Mods to S40
Post by shorty on 05/08/14 at 09:59:06

if you need help, just holler ;)

Title: Re: Initial Mods to S40
Post by HAPPYDAN on 05/08/14 at 10:30:13

Just an off-the-wall comment here. I bought my 2012 without a test ride (dumb), and frankly, if I had tested it I wouldn't have bought it. I weigh 165 lbs, and the stock shocks, even on the softest setting, rode like a hardtail (NO give!). My back and neck were screaming after 30 minutes riding. So I asked the folks here, and many agreed one the best improvements to make is get some aftermarket shocks from Progressive Suspension (for Suzuki Intruder 80 fit perfectly). That made all the difference to my ride experience. Oh, BTW - I adressed the question of harsh ride and after-firing to my dealer, and quote: "Any modificatons from stock will void your warranty.". So what. I don't need no stinking warranty! Then the stock petcock quit at +/- 1000 miles, so I rode on PRI until the raptor arrived. Best mods I could have made. Good Luck and enjoy the ride.

Title: Re: Initial Mods to S40
Post by HondaLavis on 05/08/14 at 13:09:25

Here's a pic of how I did my. It already had some washers stacked on top o the rubber tank bushings. All I purchased were 2 longer SS bolts and 2 1.5" long rubber stopper ends. I drilled a hole roughly through the middle of the rubber stoppers, and they make excellent bushings. After 2 years they've already dry rotted a little bit, but I'm sure they will last a while longer. Since I only paid ~$5 for the whole set up, I wouldn't mind if I had to replace the bumpers after 5 years or so.

The pic is from when they were new, so obviously no evidence of dry rot... ;)

http://i230.photobucket.com/albums/ee291/Lavis325CL/20121008_131442_zps55dd82b0.jpg

Title: Re: Initial Mods to S40
Post by ihasabike on 05/26/14 at 18:23:46

It rained today, so I finally got around to doing the seat mod. I tried to do what this guy suggested: http://www.jonline.org/savage/Tips___How-to_s/Tips___Tricks/tips___tricks.htm

But Home depot said they no longer sell the nylon spacers, so I had to get washers. I wound up getting 2 metric cap screws M6-1.0x60mm and 5 packs of Fender washer zinc 1/4"x1-1/4". I used the rubber grommets at the bottom as more narrow spacers at the top so that the tongue of the seat would fit in between them and rest on top of the washers.

Title: Re: Initial Mods to S40
Post by ihasabike on 05/26/14 at 18:25:32

I bought electrical tape to cover the washers, but my husband says they look good as is. What do you think?

Title: Re: Initial Mods to S40
Post by Dave on 05/26/14 at 18:28:27

I like that paint......it looks very classy.

Dave

Title: Re: Initial Mods to S40
Post by ihasabike on 05/28/14 at 18:12:28

I dropped my bike off at the local Honda dealership (they are open later than the others and I like the service guys). I gave them the viking bags and the turn signal relocation kit to mount. I also gave them the raptor petcock to install, the gran tourismo grips, and the #9 lead birdshot to fill the handlebar. They are also going to install a 12 volt connector for a GPS.

Then they told me later over the phone that neither the turn signal relocation kit nor the mounting kit for the viking bags are compatible with the S40. They said they would have to get some 'male" turn signals to use with the turn signal relocation kit, and they would look at trying to fabricate something to mount the saddlebags.

Needless to say, I'm pretty frustrated with viking bags and chrome world for specifically representing that these items are compatible with the S40. I feel defrauded, and it takes a lot for me to say something like that, with my law license and everything.

Title: Re: Initial Mods to S40
Post by ihasabike on 05/30/14 at 18:38:31

Update on the viking bags is that the mechanic said the only practical way to mount them is to soft mount them with the saddle bags supports that Suzuki makes for the S40 (part number SU-990A0-75036). That's another expensive part and who knows how long delay to get it. The money doesn't bother me as much as the delays that keep stacking up. First a delay for my bags to ship, then a delay to order the turn signal relocation kit, then a delay to find out I need these supports, and I have to wait for them too. This has been the most frustrating issue with this bike. They were also going to try and figure out some turn signals to buy since my relocation kit requires male connector turn signals. Who knows how long that will take.

Title: Re: Initial Mods to S40
Post by oldNslow on 05/30/14 at 18:47:31

7071786A787B70727C190 wrote:

Update on the viking bags is that the mechanic said the only practical way to mount them is to soft mount them with the saddle bags supports that Suzuki makes for the S40 (part number SU-990A0-75036). That's another expensive part and who knows how long delay to get it. The money don't bother me as much as the delays that keep stacking up. first a delay for my bags to ship, then a delay to order the turn signal relocation kit, then a delay to find out I need these supports, and I have to wait for them too. This has been the most frustrating issue with this bike.

Tell your installer NOT to use the hex head bolts that come with the Suzuki bag supports. Tell him to replace them with allen head or phillips head pan head bolts. The heads on the bolts that come with the supports will rub on your tire if you ever install a tire even a tiny bit bigger than the stock 140/80.

140/80s are pretty scarce. Most folks run a 140/90 when they replace the rear tire. There is a much better selection in that size.

Title: Re: Initial Mods to S40
Post by ihasabike on 05/30/14 at 19:22:12

Thanks, I will do that.

Title: Re: Initial Mods to S40
Post by ihasabike on 06/07/14 at 07:09:17

I got the bag support and went and bought the alan key bolts, but the longest I could find was 45mm, whereas the longest hex head bolt included in the kit is 50mm. I hope it works with the 45mm long bolt.

Meanwhile, I thought I was going to get my bike back for the weekend, but when they ordered turn signals, they just ordered one by mistake. So now I have to wait for another one to come in. So I guess I'm stuck riding the Gixxer for another weekend.

Title: Re: Initial Mods to S40
Post by justin_o_guy2 on 06/07/14 at 07:32:21

Just one turn signal is no problem,, If ya need to turn left, just turn right & go around the block,, lifes EASY!

Or, ya Could POINT your little finger which way you wanna go..

& then take it back & let them fix it the rest of the way,,

I guess the 45 MM bolts were long enough?

Title: Re: Initial Mods to S40
Post by oldNslow on 06/07/14 at 07:57:29

Quote:

I think they are going to be too short. The bolts that are in there now are 45mm.

Another option, since the two long(front) bolts go all the way through the chrome fender rails and are retained by an acorn nut on the outside, is to simply grind most of the head off the long bolts that came with the brackets, to reduce their height. Leave just enough to grab with a pair of needle nose pliers so your guy can tighten the nut. That's actually what I did on my bike. Put a little blue loctite on the threads.

The short(rear)bolts have to be the right length. They thread into the rails.

Title: Re: Initial Mods to S40
Post by Tocsik on 06/07/14 at 18:36:43

Is this a common problem with Viking bags? I like the look of several of their bags and the process are good, but if the taillight remount kit doesn't work, it may not be a good way to go. :-/

Title: Re: Initial Mods to S40
Post by ihasabike on 06/08/14 at 07:50:50

The tail light relocation kit I used is not the one from Viking bags. So I don't know that that's an issue. I got a nice chrome tail light relocation kit that chrome world said is for the s40, but it was not compatible with the stock tail lights.

The main problem with the Viking bags is that you can't hard mount them to the S40, but now that I understand why, I doubt that you can hard mount any saddlebags to the S40. It has the bolts on the inside of the fender instead of the outside, so there is nothing to hard mount to unless you start drilling holes in stuff.

Title: Re: Initial Mods to S40
Post by Brunkster on 06/08/14 at 19:07:52

45444D5F4D4E4547492C0 wrote:

I bought electrical tape to cover the washers, but my husband says they look good as is. What do you think?

Great color combination - I have the same on my 2013 and get comments on it all the time.

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:27:54

Finally got my S40 back from the dealer.

Mods are:

Viking Saddlebags;
Kuryakyn Turn Signal Relocation Kit.
National Cycles Custom Windshield;
12 Volt Outlet;
Gran Tourismo Grips; and
#9 Lead Birdshot Fill of Handlebars.

More photos will follow.

I have some questions. The end cap on the handlebars came off and I need to reattach it. What's the best adhesive for that?

I'd like to raise the windshield, since it is adjustable in height. What is the effect of increasing the opening between the headlight and the windshield cutout? IS it just more wind to the body or something else?

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:29:52

Saddlebag Mounts

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:30:37

Turn Signal Relocation

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:31:26

Windshield mount

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:32:10

Windshield postion

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:33:00

Gran Tourismo Grips

Title: Re: Initial Mods to S40
Post by ihasabike on 06/15/14 at 20:33:46

12 volt outlet

Title: Re: Initial Mods to S40
Post by WD on 06/15/14 at 22:56:18

You'll get some road noise from the gap.

They cut the end off the grips to reinstall the chromed plastic one shot wonder bar end covers? That's different... Super glue should affix them alright. Scuff up the inside of the bar with an emery board to give the glue a fighting chance at some mechanical adhesion.

Title: Re: Initial Mods to S40
Post by justin_o_guy2 on 06/16/14 at 01:17:25

Hey, Hasbike,,you ever run to Shreveport, gimme a holler first,, maybe we could all meet up for coffee in Longview,,

Title: Re: Initial Mods to S40
Post by ihasabike on 06/16/14 at 04:56:09

3526620 wrote:

vvvvvvvvvvvvvvvvvvvvvvvvv
^^^^^^^^^^^^^^^^^^

So just road noise? I was kind of worried about it affecting handling. One thing I noticed after installing the windshield is when I road at high speed into a strong wind, the bike started fishtailing a little bit, as if the wind were pushing the shield back and forth and turning the handlebars slightly in an oscillating manner.

I had no idea they were going to do that to the grips. Thanks for the tip on the superglue. I want to affix a throttle boss to the end of the throttle grip, so I hope it holds.

Now I'm trying to figure out where to mount my iPhone docking station. The handlebar seems overly full.

Title: Re: Initial Mods to S40
Post by ihasabike on 06/18/14 at 17:03:09

594640475A5D6C5C6C54464A01330 wrote:

Hey, Hasbike,,you ever run to Shreveport, gimme a holler first,, maybe we could all meet up for coffee in Longview,,

We went to Shreveport a couple of times in the past. Anything's possible. :-)

Title: Re: Initial Mods to S40
Post by PuffsPlus on 06/18/14 at 17:41:32

WD, could you pm me and tell me how you installed the bags on your stock Savage that is pictured in this thread. I have the same set and have no idea how to get them to look as tight and professional as yours. :o

Title: Re: Initial Mods to S40
Post by Kay.mac on 06/25/14 at 10:03:26

Hi! I am also struggling with my new Viking bags. I'm brand new to bikes, and also brand new to mechanics. (Understanding the human body? No problem. Who knew machines were more complicated.) I spent the ENTIRE weekend trying to get my saddle bags on. They have shock cutouts, and were supposedly designed for a S40. (Although I'm pretty sure Viking bags has never seen a s40 before). I have a '14, with a sissy bar and OEM saddle bag supports. Ultimately I had to soft mount the bags, and have the shock cutout around the saddle bag support. I relocated the tail lights using the Viking 'universal' turn signal relocation kit and some cheap turn signals I got off eBay, which look fairly similar to the stock set. I'm not crazy about them, so will probably look for nicer ones soon.
Unfortunately, with this set up the saddle bags are pushing back on the turn signals pretty hard. I'm worried they might get broken off if I hit a bump, or just get turned so they're facing up towards the sky rather than straight back. Also, I feel like the bags aren't super secure as they are only held by the soft yoke on top, and the slightly flimsy strap on the borrow which I've tied to the saddle bag support.
So: can you please share with the group at large how you got the bags attached to the saddle bag supports so nicely? Also, is anyone else having the problem of saddle bags pushing back against the turn signals? Is this actually a problem or is it ok?

Thanks so much guys! This forum has been such a blessing!!

Kate

Title: Re: Initial Mods to S40
Post by ihasabike on 08/11/14 at 18:04:54

The motorcycle mechanic that soft mounted my bags with the OEM supports punched little holes in the bags on both sides of the support rods in multiple locations and used zip ties from the inside to wrap around the support rods and get a tight fit.

My bags are not hitting the relocated lights. If you are having that problem, then you might consider getting the kind of lights that attach to the rear of your saddlebags, instead of the license plate mount.