SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> Bryan's Build Thread
/cgi-bin/YaBB.pl?num=1399663702

Message started by BryanA on 05/09/14 at 12:28:22

Title: Bryan's Build Thread
Post by BryanA on 05/09/14 at 12:28:22

Not too sure where this is going, but I wanted to document things before I got too far into this.

Picked up this girl off a buddy for 500 bucks.

http://i26.photobucket.com/albums/c117/claark/ls650/5EC7B203-7689-412B-834B-950C230F5AC7_zps1ghqt6lg.jpg (http://s26.photobucket.com/user/claark/media/ls650/5EC7B203-7689-412B-834B-950C230F5AC7_zps1ghqt6lg.jpg.html)

http://i26.photobucket.com/albums/c117/claark/ls650/D8F80F34-09ED-4530-A6E7-E39421D6E3AC_zpslhcxgw5y.jpg (http://s26.photobucket.com/user/claark/media/ls650/D8F80F34-09ED-4530-A6E7-E39421D6E3AC_zpslhcxgw5y.jpg.html)

2001 LS650 - 10,300 miles

Of course it needed a new battery....so in THAT went...fresh tank of gas, and a little STP treatment :) and off to the parking lot it went.

Upon initial inspection, it needed a carb cleaning....BAD...

And...

The baffles were grossly cut out of the exhaust:

http://i26.photobucket.com/albums/c117/claark/ls650/A26521DD-2CCE-4ADA-B028-CB3C03FF91BF_zpsaypksybo.jpg (http://s26.photobucket.com/user/claark/media/ls650/A26521DD-2CCE-4ADA-B028-CB3C03FF91BF_zpsaypksybo.jpg.html)

So apart she went.

Started with cleaning the carb....

And Discovered this:

http://i26.photobucket.com/albums/c117/claark/ls650/7303E5D5-DFB9-4BF1-8519-0E846EA88A0A_zps8uzmf7or.jpg (http://s26.photobucket.com/user/claark/media/ls650/7303E5D5-DFB9-4BF1-8519-0E846EA88A0A_zps8uzmf7or.jpg.html)

That's a 230 main jet! Not too sure where that came from...but it wasn't from Suzuki....So time for jets and while I'm at it....exhaust too. I found from my research, that with a Dyna muffler and stock airbox, I'd be looking at somewhere near a 155 main and 52 pilot. I'm considering tubbing out the airbox and doing something similar to this:

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1295745373

(I really fell in love with that mod)

So along with the pipe I ordered 155.5/52.5 jets from Jets R Us.

Now I'm just waiting on fedex!

And you're all caught up. :P

Title: Re: Bryan's Build Thread
Post by sailorcolin on 05/09/14 at 13:03:26

looking forward to seeing the build! How many miles?

Title: Re: Bryan's Build Thread
Post by Dave on 05/09/14 at 13:14:20

Well....it is a bit late for this....but I would have suggested you get a main jet down to a 150.....and pilot down to a 50 while you were ordering them. I think a lot of folks are jetting the bike too rich, and a #155 is usually too rich.

With a stock air box and Dyna Muffler....a #150 main and #50 Pilot and 2 washers on the needle my bike ran the best.

Title: Re: Bryan's Build Thread
Post by BryanA on 05/09/14 at 15:37:16

546F6275646873756E666B74070 wrote:

Realistically, I should have gotten them both, since I plan on doing the intake as well. May have to do it sooner than I thought. :P

Exhaust came in! Not bad for 30 bucks shipped on ebay!

http://i26.photobucket.com/albums/c117/claark/ls650/06DE619C-172D-4485-89E4-5F2898FA7B32_zps6npca4qu.jpg (http://s26.photobucket.com/user/claark/media/ls650/06DE619C-172D-4485-89E4-5F2898FA7B32_zps6npca4qu.jpg.html)

Hopefully Jets should be here tomorrow!

But I also noticed this today.....

http://i26.photobucket.com/albums/c117/claark/ls650/A4F3B09B-BB39-47F5-B19F-6C0AA80AEB7D_zpsjbltf86h.jpg (http://s26.photobucket.com/user/claark/media/ls650/A4F3B09B-BB39-47F5-B19F-6C0AA80AEB7D_zpsjbltf86h.jpg.html)

That would be oil coming from the head gasket....

Oh, and It's got 10,300 miles on it. (For Sailor)

Title: Re: Bryan's Build Thread
Post by ToesNose on 05/09/14 at 19:30:10

Good choice on the Dyna muffler, experiment a little an intermediate pipe makes it sound real nice 8-)

Title: Re: Bryan's Build Thread
Post by Dave on 05/10/14 at 04:02:43

Nope.....not head gasket. It is most likely the rubber head plug. We have never seen a Savage head gasket fail.....yet.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1099227295

Title: Re: Bryan's Build Thread
Post by justin_o_guy2 on 05/10/14 at 08:32:14

Thats how to get into a bike,, 500 bucks & some sweat equity & youll be good to go.. YOu shouldnt be in it more than 600 when youre out & riding, unless the tires are old or worn out,,
Be gentle with that exhaust pipe,, its only held by 2 skinny little bolts going into that aluminum head,,If pulling the old or installing the new requires much grunt, youd better pull the header off the motor.,

YOure at 10k miles,, YOull need to have a look at the cam chain in a few thousand,
& Dont pull the plug w/o blowing the crap out from around it,

Im always sayin that, I did it once & spent a coupla hours with different things pokin in there with toilet bowl wax on it, dabbing out bits of crunchy stuff that fell in,, urinated me right off, that did..

Title: Re: Bryan's Build Thread
Post by BryanA on 05/10/14 at 20:26:41

0A313C2B3A362D2B3038352A590 wrote:

Nope.....not head gasket. It is most likely the rubber head plug. We have never seen a Savage head gasket fail.....yet.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1099227295

<3 U Dave! You made my night! I was just sitting here thinking I'm gonna hate replacing that thing, Going to look further into this fix.

091610170A0D3C0C3C04161A51630 wrote:

Thanks for the heads up. Exaust header has to come off anywayz...It's missing a bolt! HAHA! Cant complain for 500 bucks though! Is the chain something I can look at with the head cover off?

Title: Re: Bryan's Build Thread
Post by S-P on 05/10/14 at 20:51:46

517E77757C7F727A100 wrote:

Is the chain something I can look at with the head cover off?

You'll want to check the cam chain tensioner. Chances are the chain itself is OK at that mileage unless it was seriously abused. Check out the multiple threads on the tensioner. You need to pull the clutch side cover to see that.
At 10K, definitely want to do that before you do any serious riding. Mine had about 9K on it at the tensioner was about to fall out and it needed the plug cap fixed (mine was leaking oil exactly like that).

Title: Re: Bryan's Build Thread
Post by BryanA on 05/12/14 at 19:42:09

Thanks for the tensioner tip! Added to the list.

Got the carb rejetted and new pipe, temporarily, installed. (see pic)

Ran like a CHAMP on the stock airbox. Next up it to clean up the fitting and get it ready to paint. I'm going to paint it and leave the accents chrome. Anyone have a good lead on a new heat shield for the area over the joint? I might go with the stock one but it looks a little odd with the HD pipe.

Next up...Valves, plug(to fix that darn oil leak) and chain tensioner (Thanks S-P)

http://i26.photobucket.com/albums/c117/claark/ls650/D1165F49-5536-4B4E-9B33-1ACB439AA671_zpsyv2zsyay.jpg (http://s26.photobucket.com/user/claark/media/ls650/D1165F49-5536-4B4E-9B33-1ACB439AA671_zpsyv2zsyay.jpg.html)

Title: Re: Bryan's Build Thread
Post by justin_o_guy2 on 05/12/14 at 21:09:17

You need a T-clamp

https://www.google.com/search?q=t-bolt+clamps+stainless+steel&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-US:official&client=firefox-a&channel=sb

Title: Re: Bryan's Build Thread
Post by BryanA on 05/13/14 at 23:48:39

3B242225383F0E3E0E36242863510 wrote:

You need a T-clamp

https://www.google.com/search?q=t-bolt+clamps+stainless+steel&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-US:official&client=firefox-a&channel=sb

BEAUTIFUL! That's exactly what I was looking for!

Thank you!

I also discovered the petcock started acting up (still the stock one). It started stumbling BAD, till I flipped it to PRI...looks like I'll be replacing that too.

;D

Title: Re: Bryan's Build Thread
Post by BryanA on 05/19/14 at 14:21:32

Lots of work in my future. Ordered, a oil plug, had the exaust sand-blasted(I have a friend), new petcock, AND checked the chain tensioner.

So. I have a buddy that cleans and paints industral tanks and vessles. Had him prep my exhaust for VHT Paint Next week

http://i26.photobucket.com/albums/c117/claark/ls650/B0FF4C43-7F9F-4DDC-9B4D-7A38DD16A335_zpsxsxbarpw.jpg (http://s26.photobucket.com/user/claark/media/ls650/B0FF4C43-7F9F-4DDC-9B4D-7A38DD16A335_zpsxsxbarpw.jpg.html)

Where's all the shiny go!! It's almost sad huh!

Pulled the clutch cover off and checked the cam chain:

http://i26.photobucket.com/albums/c117/claark/ls650/87AB31D7-C408-4C0E-8184-421856AC7705_zpsvrkki5gx.jpg (http://s26.photobucket.com/user/claark/media/ls650/87AB31D7-C408-4C0E-8184-421856AC7705_zpsvrkki5gx.jpg.html)

http://i26.photobucket.com/albums/c117/claark/ls650/AA941891-7B0B-43FD-98DA-23B748E1373D_zpsjm6virxw.jpg (http://s26.photobucket.com/user/claark/media/ls650/AA941891-7B0B-43FD-98DA-23B748E1373D_zpsjm6virxw.jpg.html)

Not bad. For those of you mechanicly challenged .68 inches displacement. So....I'm not parking it, but I already got in touch with Versy about a new tensioner.

Next up, changing out that oil seal in the head and paint on the exhaust!

Title: Re: Bryan's Build Thread
Post by S-P on 05/19/14 at 21:53:06

Yer doing it right! I used my stock exhaust guard on my Dyna pipe and it does look a little big, but I figger no one really "sees" it at 60mph anyway... ;D An old Greek saying, "Many will see, but few will notice..." ;)

Title: Re: Bryan's Build Thread
Post by WD on 05/20/14 at 07:57:31

VHT high heat paint is garbage, has been since the 90s. Spend the extra money for ceramic coating. The paint will burn off of the first few inches of header pipe within a week or two.

Title: Re: Bryan's Build Thread
Post by Dave on 05/20/14 at 08:24:05

If you paint it with spray paint.....it will hold up for a while, look somewhat funky in the process, and need to be redone frequently. Sitting outside or riding it in the rain has a big effect on the durability of the paint. When the paint is subject to heat cycles it gets small cracks in it....and moisture quickly starts to make it fall apart. Any road crap, oil or bugs thrown onto the paint will permanently stain it.

Like WD says.....if you can afford a bit of time and money getting it done right....do it now. I bookmarked this place as a promising place to send it. $ 45 to $ 65 for a muffler, $ 14 a foot for the header.
http://boneheadperformance.com/

Maybe you can find a place to get it done locally and save some time and shipping cost...but beware not all places are equail. A local powder coating place made some attempt to spray and bake on ceramic coating......with mixed results. Sometimes it would hold up OK - but most times it did not. What they found out was that we have too high of a humidity in Northern Kentucky for this process. In the short distance from the powder gun to the header/muffler a small bit of moisture is picked up from our 80-90% humidity....and this greatly effects the durbility of the ceramic coating. The humidity of the air has to be very low when spraying ceramic coatings.

Title: Re: Bryan's Build Thread
Post by BryanA on 05/21/14 at 11:36:55

Well I wish I had read this before I bought paint. HAHAHA! I found a place that will do it local and they have a great rap for quality work and the price is good. But It's not in this months budget. AND they have to sandbast them again anyway....SO I thought I'd have a little fun and try my hand at the spray job. Seeing as how I'm gettin em redone anyway.

Here's my humble spray booth with my parts ready to go.

http://i26.photobucket.com/albums/c117/claark/ls650/96D0A658-1404-4BD7-9780-9D4C9887C566_zpsyezz66hl.jpg (http://s26.photobucket.com/user/claark/media/ls650/96D0A658-1404-4BD7-9780-9D4C9887C566_zpsyezz66hl.jpg.html)

First coat:

http://i26.photobucket.com/albums/c117/claark/ls650/3035448D-AF3E-42B6-BF88-6EF4B75FB484_zpsd26urssx.jpg (http://s26.photobucket.com/user/claark/media/ls650/3035448D-AF3E-42B6-BF88-6EF4B75FB484_zpsd26urssx.jpg.html)

And finished (3 coats later):

http://i26.photobucket.com/albums/c117/claark/ls650/E29A64BC-8C47-40C8-B6AB-CEA328A57B22_zpsuu9pfjon.jpg (http://s26.photobucket.com/user/claark/media/ls650/E29A64BC-8C47-40C8-B6AB-CEA328A57B22_zpsuu9pfjon.jpg.html)

http://i26.photobucket.com/albums/c117/claark/ls650/A0F3C213-B644-4D42-8E96-B4D1DC4E5BD4_zps1ohg8gnb.jpg (http://s26.photobucket.com/user/claark/media/ls650/A0F3C213-B644-4D42-8E96-B4D1DC4E5BD4_zps1ohg8gnb.jpg.html)

And installed: http://i26.photobucket.com/albums/c117/claark/ls650/826F131B-C748-4087-9CF9-794961790CEE_zps7q0et4a5.jpg (http://s26.photobucket.com/user/claark/media/ls650/826F131B-C748-4087-9CF9-794961790CEE_zps7q0et4a5.jpg.html)

Should have my new clamp in the next couple days. Also picked up this little heat shield for 30 bucks from Samson Exaust

http://i26.photobucket.com/albums/c117/claark/ls650/00A3C1AA-0657-4B5F-8D19-3EEF3F5769C9_zpsczvge215.jpg (http://s26.photobucket.com/user/claark/media/ls650/00A3C1AA-0657-4B5F-8D19-3EEF3F5769C9_zpsczvge215.jpg.html)

It wont fit with the big muffler clamp but I'll get some pics with the new clamp on it next week.

Went through the recommended curing process. 10m idle and cool down, followed by 20 and then a 30m ride and complete cool down.

Hoping it lasts at least a month.

Got this in via fedEx today:

http://i26.photobucket.com/albums/c117/claark/ls650/85DF322C-06C2-407F-A388-409B74900FAB_zpsmcejj8fr.jpg (http://s26.photobucket.com/user/claark/media/ls650/85DF322C-06C2-407F-A388-409B74900FAB_zpsmcejj8fr.jpg.html)

So I'll be starting on that tonight. Shes almost ready to go!! Looking for a windshield though I think...freeway speeds are kinda hard I've noticed.