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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> 96 jockey shifted bobber build /cgi-bin/YaBB.pl?num=1431568873 Message started by Rylee on 05/13/15 at 19:01:11 |
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Title: 96 jockey shifted bobber build Post by Rylee on 05/13/15 at 19:01:11 Finally got some free time today to head over to my buddies shop and get the thumper on the lift. Had a box full of parts and a plan. Got my RYCA clip ons installed. Exhaust buttoned up and finally tuned properly. And got my jockey shift fabbed up and in good working order. I basically cut the foot shifter mechanism off the forward control assembly. I cut the stud with snap ring that holds the shift lever off the forward control. Took about 1/4" off the width of the sleeve for the shifter and fabbed up a mount system that was welded to the hardtail lower tube. I then flipped the linkage around so the shift pattern was still the same. Forward or down is 1st and back or up is 2-5. Used 1" thin wall tube for the jockey stick so I could mount my stock clutch lever. The throw between 1st and 2nd is further than I assumed it would be but I understand the physics of longer lever longer distance of action. I was surprised at how sturdy everything came out. The jockey lever doesn't have unnecessary play and is actually quite still while riding. Think I'm gonna go back in it and just do some flat stock for the jockey stick and add enough 1" tube at the top to mount the clutch lever and grip. Trying to make it as light as possible yet still solid enough for the rigors of shifting. All in all I'm super happy and it feels good to be back to a jockey shift bike. |
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Title: Re: Hand clutch jockey shift built and working... Post by gizzo on 05/13/15 at 19:30:14 That's a very cool looking scooter. How does it look with a rider on board? Neat exhaust. I bet that's loud! :D I'm guessing the whole weight of the jockey lever and clutch lever + cable is hanging on the shift shaft at the gearbox? That would be quite a load to be putting on that little shaft. I can see it bending, or the bush it runs in flogging out, or extra wear and tear on the shift forks as the lever bounces around. Would it not be better to have a jockey lever mounted to the frame with lighter weight shift rods to the gearbox? +, would look tidier and cooler IMO only. I've never bothered to look closely but I'm guessing that's how it works on flat tankers with the shift quadrant arrangement up by the tank. What do you think? |
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Title: Re: Hand clutch jockey shift built and working... Post by Kris01 on 05/13/15 at 19:33:49 I'm not knocking it but I'm just wondering...why would you want to make it unnecessarily difficult to shift? That looks dangerous to me. |
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Title: Re: Hand clutch jockey shift built and working... Post by Rylee on 05/13/15 at 20:06:00 @gizzo The jockey rod is mounted via a sleeve between 2 tabs welded to the hardtail section. It is connected to the shift shaft via the stock linkage. So there's no weight on the shift shaft itself. My original idea was the just mount the jockey stick directly to the shift shaft but for the issues you addressed I ended up going with the shifter being hard mounted between tabs. I used the stock shift lever to accomplish this. The sleeve that the lever is welded to trimmed and the original stud with snap ring was cut from the forward control and welded into the mount system I fabricated giving it a stock like appeal. Doing this allowed me to use the stock linkage. It just runs to the rear of the case instead of forward. I took a picture but the lighting is terrible @Kris01 It's actually very easy to shift. After 2nd if your bike is in good mechanical order the clutch is rarely needed. I simply tap the jockey stick to me and hit gears easy. Hardest part to get use to is making right turns from a stop. The angle requires a pull on the bars and with only 1 hand on it's a bit of a trick to learn. I rode 2 years on my old bike with jockey. When I bought it the PO had a foot clutch system. That lasted 3 months and I swapped it out for a hand clutch. Fell in love and have wanted to do it every since I got the savage. |
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Title: Re: Hand clutch jockey shift built and working... Post by gizzo on 05/13/15 at 22:07:46 I see... Nice work! 8-) |
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Title: Re: Hand clutch jockey shift built and working... Post by Rylee on 05/13/15 at 22:15:18 @gizzo I went a little over the top with gussets on the mount tabs for the jockey stick. Until it was all bolted in and under it's own weight I wasn't sure if just the 2 mounting tabs would support the nearly 3' of shift lever tube. Now I just need to respray the rest of the frame. It's dingy and scuffed everywhere and that 6" of area I welded in has fresh shiny gloss black paint. Still thinking about removing the 1" round stock and replacing it with either some 1/2" solid stock or flat stock to shave a bit more weight off the shift rod. |
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Title: Re: Hand clutch jockey shift built and working... Post by gizzo on 05/13/15 at 22:53:44 Close up pic??? Loving the bits you've used: seat, tank, gauge and pipe all look great. |
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Title: Re: Hand clutch jockey shift built and working... Post by corey v84 on 05/14/15 at 02:30:10 I would be interested in buying one, if you would make me one! |
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Title: Re: Hand clutch jockey shift built and working... Post by Rylee on 05/14/15 at 09:38:45 @corey v84 As I would love to market such a kit what I built requires a hardtail because that was my platform. And the mounting system I built requires welding and I'm not sure if I duplicated it in a "weld on yourself" form the same result would happen. This was a I cut it up and made it as I went deal. My buddy who owns the shop when I finished was all "I didn't see that as the end result when you explained it" because I kinda just shot from the hip and as it came together so did my idea. @gizzo I'll take some pics now that there's better lighting |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 05/14/15 at 21:18:26 Realized today I should have just do t a build thread for this bike. I PM'ed Dave about it but it would be more work than I want to dump on any moderator to piece together different threads so I'll just use this one as my build thread. So here's links to other aspects of the build and a walk thru of what I've done http://suzukisavage.com/cgi-bin/YaBB.pl?num=1425621235 Tensioner replacement thread |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 05/14/15 at 21:23:44 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1429405934 Original post of gauge install. Here a shot of te new location due to jockey shifter |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 05/14/15 at 21:25:48 Building the exhaust took a few tries. I was happy with the 1st times routing and location but "over" baffled it and by the time is cut it open enough times to get it close to right I wasn't that happy with it |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 05/14/15 at 21:29:02 Second time around I decided to open up the right rear for a hard tail bag so I routed the pipe 90* thru the opening in the frame under the carb. Used a torque cone and a crumb cup and got the baffling needed and sound I wanted. |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 05/20/15 at 13:28:31 The last few days I've noticed a bad vibration in the gas tank and couldn't figure out why. Pulled the tank off and 2 of the rivets for the RYCA mount had come undone. So I pulled the whole system apart and welded in new mounts. Also noticed the top of the carb was against the original mount and had rubbed the metal pretty good causing a solid groove...not good |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 06/23/15 at 22:12:16 Haven't posted in the build thread for a bit but a lot has changed. Finished up the speed hump/seat pan. Built a headlight fairing out of a honda shadow front fender. Redid the exhaust for the 4th time. |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 06/24/15 at 00:22:06 Built a new exhaust today. Played with the baffling but it needs a bit more. I did a ride tonight of about a 25 mile round trip and noticed the bike was running a bit hotter which indicates a leaner setup so I'll have to make so e tuning adjustments. Throttle response felt good but I was getting decel pop more than normal and like I said I could feel increased heat so she's definitely lean. First time ever making a Y-pipe from scratch and I am happy with the outcome. Always wanted duals on a single! |
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Title: Re: 96 jockey shifted bobber build Post by Canadian_kiwi on 06/24/15 at 18:09:50 Nice build! Very different than anything else |
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Title: Re: 96 jockey shifted bobber build Post by chzeckmate on 06/25/15 at 22:35:41 Dang, that's cool! |
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Title: Re: 96 jockey shifted bobber build Post by strang on 06/26/15 at 06:14:57 radient |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/15/15 at 17:36:14 Now that my sporty is "done" I can focus on the Savage again. Since I have a daily I can actually do work that doesn't have to be finished by the end of the day and bike put back together. Got my tins back from paint today. |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/15/15 at 17:38:24 Bike is stripped down so I can respray the entire frame. Im gonna pull the engine in the morning and go thru it and make sure it's solid. Fix a few leaks and paint it black. Waiting on wheels to get back from powder coating. Decided to go back to black and have them done right instead of rattle canned! |
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Title: Re: 96 jockey shifted bobber build Post by Art Webb on 07/16/15 at 14:36:34 such a busy guy i wish i had the ambition to tackle the issues with my XS right now lol |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/17/15 at 21:45:40 And done! Well not done still needs the back pad which the leather guy is dying as I type (just got a text saying he was about to dye the leather now) and once the back pad is on I will match the graphics to the tooling in the pad. A few small details still to do and I have yet to make the chin spoiler. Otherwise she's super close... |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/17/15 at 21:46:10 Exhaust side shot |
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Title: Re: 96 jockey shifted bobber build Post by Art Webb on 07/18/15 at 11:39:23 Looks good |
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Title: Re: 96 jockey shifted bobber build Post by EJID on 07/18/15 at 14:54:46 Good looking bike there... Makes me wonder how that rear tire handles though :-/ |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/23/15 at 13:32:37 Finally all of the fabrication work is done. Finished up the chin spoiler yesterday and got it mounted. |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/23/15 at 13:33:02 Side shot |
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Title: Re: 96 jockey shifted bobber build Post by nof1 on 07/23/15 at 14:58:52 Nice! Love the low chopped look. How's it ride? My last hard tail had a super thin seat but not like yours ;D Do you keep the back tire a touch soft or just deal with it? |
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Title: Re: 96 jockey shifted bobber build Post by Art Webb on 07/23/15 at 15:09:34 looks sweet, but I'd be scared to ride it, my stocker kills my butt as it is ;D |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/23/15 at 21:43:15 @nof1 Since it's a heavy biased tractor tire I run it at 20psi and it has a bit of bounce. Seats really not that bad due to the seated position. I'm sitting knees just past 90 so my thighs are more on the seat thanot my arse. The back pad that's still not done is what I need most. Under acceleration the majority of my weight is pushed against it. Once the back pad is on I'll be ok. |
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Title: Re: 96 jockey shifted bobber build Post by Art Webb on 07/23/15 at 21:52:37 Well that makes sense, remembering what I read on the seat mod site I'd run that tire at 20 or so, too |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 07/26/15 at 21:47:57 Got to park the bike at the Bobbers N Choppers booth today and had a lot of great feedback. Finally got the graphics on, still waiting on the back pad from the leather guy. Had a few sale offers for some respectable prices. Was nice to know what I could ask for it if I ever wanted to sell it. Most common questions were "how's that seat feel" and " is that shifter hard to work" |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 08/20/15 at 00:01:54 Decided to keep the bike and go forward with a few things. I picked up a spare rear wheel off ebay and it's currently at Buchanans having the hub laced to a 19x2.5 spin werks hoop. Once that's done the entire back half of the frame will be removed and cut off for a board track style hard tail install. Going to stretch the rear 3 more inches, do a vertical oil bag cut open to house electronics and lower the bike 2 more inches to compensate for the 19" rear. Jockey shift is removed. Front end has been cleaned up including all wiring removed from clip ons. Internal throttle is ready to go on leaving that side completely free of any clutter. Relocated starter to push button tucked into frame rail between seat and tank. Double throw toggle now serves as turn signal and actuates dual rear led tail lights and bottom mounted led driving lights with amber leds for turns. High beam is connected to driving lights all actuated thru a switch tucked into the headlight housing. Got bored today at the shop and made aset of moon disc covers for the old 15" wheel. Really love the look so I may have to make a set for the 19" rear when it's done and on the bike. |
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Title: Re: 96 jockey shifted bobber build Post by Rylee on 08/20/15 at 00:05:25 Finished product on the bike. I took the wheel over to the tire shop across the street once it was installed and all buttoned up and to my surprise on the balancer it only showed being a half ounce out of balance. Made me kinda fuzzy inside to know I was that on with the truing of the disc! |
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Title: Re: 96 jockey shifted bobber build Post by Violent_Rage on 08/20/15 at 02:45:44 Awesome!!! :o Very good job! |
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Title: Re: 96 jockey shifted bobber build Post by strang on 08/20/15 at 03:11:19 dude love the wheel cover! |
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Title: Re: 96 jockey shifted bobber build Post by chzeckmate on 08/21/15 at 01:12:49 Nice work! |
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Title: Re: 96 jockey shifted bobber build Post by DesertRat on 03/20/16 at 18:26:00 Rylee, that is one stellar bike mod ... |
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Title: Re: 96 jockey shifted bobber build Post by Dave on 03/21/16 at 03:08:43 Rylee mysteriously vanished in November 2015. I tried to reach him by Personal Messages, telephone and email contacts, and I could not reach him. |
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Title: Re: 96 jockey shifted bobber build Post by DesertRat on 03/21/16 at 06:31:17 that sucks to hear Dave |
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Title: Re: 96 jockey shifted bobber build Post by justin_o_guy2 on 03/21/16 at 14:01:18 142F2235242833352E262B34470 wrote:
That's really odd. What's the last post he made? I mean date, Not literally The last post.. What happened when you called? When someone just falls off the grid, well, that bothers me. I hadn't spotted that he was gone,, I should have... |
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Title: Re: 96 jockey shifted bobber build Post by DesertRat on 03/21/16 at 14:05:25 Justin, Last Online: 11/15/15 at 11:41:56 Last Post:10/23/15 at 19:29:31 view » Re: Saddle bags, tool bags, handles bars misc stuf Last PM: 10/27/15 at 20:26:43 |
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Title: Re: 96 jockey shifted bobber build Post by Dave on 03/21/16 at 14:07:36 The last post he made was in response to his listing in the Marketplace. When I called his phone I got a recording for messaging.....he never returned my calls or the one that Verslagen left. He never responded to any emails or Personal Messages, he never again logged onto this forum. I had bought some parts from him, paid using PayPal......they tried to contact him and they never got a response, and I got my money refunded through PayPal. I believe Rylee was honest and did not do this intentionally - I am concerned that he has something happen to him (remember....we have a somewhat dangerous hobby). |
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Title: Re: 96 jockey shifted bobber build Post by justin_o_guy2 on 03/21/16 at 14:08:04 I'm not too much of a tech... Jerk, possibly, not a tech... nope,, |
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Title: Re: 96 jockey shifted bobber build Post by DesertRat on 03/21/16 at 19:38:04 getting hurt, that was my first thought Dave ... just don't like thinking like that, but it's a dangerous hobby indeed ... |
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