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Message started by Tocsik on 06/15/16 at 10:06:05

Title: Odd (dangerous?) sensation hitting bumps at speed
Post by Tocsik on 06/15/16 at 10:06:05

Just installed a Kawasaki front pulley and everything seems ok except for when hitting bumps at highway speeds.  It feels like the rear wheel almost locks up or binds when I hit these and it's pretty startling.  I've checked and rechecked the axle and shock bolts/nuts and they are OK.  The belt doesn't look like it's suffering any abuse.  I'm running it a little looser than before because it seemed to get tighter on me and started making noise.

The only thing I did different was to decrease the preload on the rear shocks by 2 clicks because I had them all the way up.  I bought the pulley from Dave so it's professionally machined and it's not contacting anywhere after I made a few modifications.  The belt seemed to contact the lower oil seal retaining plate screw after everything was all bolted up (the stock hex head is replaced with a button head screw and even that's filed down a little).

Anyone else notice anything like this?  It's not a front end wobble; more a rear end shudder or binding and it wasn't there with the stock front pulley in place.  I will probably re-adjust the rear shocks the way they were before to see if that makes a difference but I have to remove my saddle bags to do that.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by justin_o_guy2 on 06/15/16 at 10:13:33

Looks like the Easiest first step is change your shocks back.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Dave on 06/15/16 at 10:15:34


2E3137302D2A1B2B1B23313D76440 wrote:
Looks like the Easiest first step is change your shocks back.


Check the back tire/fender for any signs of rubbing....maybe the back tire is hitting the fender, saddlebag supports or bolts when the suspension bottoms out.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by old.indian on 06/15/16 at 10:17:53

I installed the 25 tooth front pulley too, and I'm not having any problems . I WAS bottoming out on bumps with the original shocks when I dropped the pre load from 5 to 4, And that was with the ORIGIONAL front pulley.....      FYI.. I installed Intruder 800 shocks as part of the project, MUCH better ride, and NO bottoming out.....    :)

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/15/16 at 10:21:10

Indian, were the shocks bolt-on or were other changes needed?  Bushings, different belt setting etc?  I've been considering this, too but haven't done the research yet so thought I would cheat and just ask ya.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by WD on 06/15/16 at 10:48:21

Direct bolt on. Ran them on the 98, run a Progressive version on the 03. The rear fender gap will get larger and you'll likely need to loosen the belt a bit. Plan to relearn the bike's handling, as you will have a noticeable weight shift forwards.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by old.indian on 06/15/16 at 11:21:08


1D0E4A0 wrote:
Direct bolt on. Ran them on the 98, run a Progressive version on the 03. The rear fender gap will get larger and you'll likely need to loosen the belt a bit. Plan to relearn the bike's handling, as you will have a noticeable weight shift forwards.

Per WD... BUT you will need to trim the belt guard and the belt tension WILL be affected .
8-)  Major improvement in the ride though... :)   

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/15/16 at 11:25:14

Ah.  So I will most likely need to extend the swingarm slot then to get enough movement in the belt as I'm pretty much all the way forward with the 140/90 rear tire and Kawi front pulley.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by old.indian on 06/15/16 at 11:34:22


122925352F2D460 wrote:
Ah.  So I will most likely need to extend the swingarm slot then to get enough movement in the belt as I'm pretty much all the way forward with the 140/90 rear tire and Kawi front pulley.

I didn't need to, and I have a tall Michelin 140/90-15 along with the 12" Intruders And the 25 tooth front pulley..... Close, BUT not a problem.....  

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Dave on 06/15/16 at 11:39:19


1E25293923214A0 wrote:
Ah.  So I will most likely need to extend the swingarm slot then to get enough movement in the belt as I'm pretty much all the way forward with the 140/90 rear tire and Kawi front pulley.


I believe the belt becomes a bit looser with longer shocks...not tighter.  When the there is a straight line between the front pulley, the pivot point for the swing arm, and the rear axle....the distance between the front/back pulley is the longest - and that situation occurs with the stock length shocks.  When you put longer shocks on the bike the swing arm angles down, and the distance between the pulleys is reduced slightly.

The change in belt tension while riding does change a bit more with the longer shocks however....so it is better to run the belt just a tiny bit looser when using the longer shocks.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by justin_o_guy2 on 06/15/16 at 11:47:09

Would that be a pinch or a dash?

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/15/16 at 11:53:03

OK.  So longer shocks it is!  Time for some shopping.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/15/16 at 12:35:45

Yikes.  Pricey bits.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by justin_o_guy2 on 06/15/16 at 12:46:50

You proved it's the shocks?
Sure you got them set even?

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/15/16 at 13:20:31

Thanks JOG.  I think I have more investigation first but have been considering the longer shocks anyway.
I need to be sure nothing is hitting with the shocks adjusted as they are first.  Wish I could get some adjustment before riding home from work today but the hard saddlebags are preventing me getting access.  I'll take back roads home which is more fun anyway (esp with temps in the 90's; darn stop and stop traffic).

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Dave on 06/15/16 at 13:27:25

You can find good factory Suzuki 800 Intruder shocks on eBay for $40 - $ 80 bucks that are really nice - but you have to sort through a lot of crappy ones to find the good ones.

It does take some time to find a nice set.

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/15/16 at 18:10:35

Which direction to turn the lower adjuster on the rear shocks to stiffen them up? It's hard to see in there where the detents are and also feels like the probably turn different directions. Just can't remember from the one other time I adjusted them.

Looking up the lower shock perch from underneath, it looks like the longest/tallest detent provides the stiffest ride.  Is that right?

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Kris01 on 06/15/16 at 20:45:55

Here ya go:

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by Tocsik on 06/16/16 at 11:10:33

Thanks.  I got 'em adjusted yesterday afternoon and discovered you can accidentally go from 5 to 1 by turning too far, but you can't turn it back. You can see in the pic you provided that it's possible to go from 5 to 1, but not from 1 to 5.  Then, you have to remove the shock, rotate the bottom collar so the adjuster port is back around, remount the shock and continue on.  Just a little FYI tidbit for anyone else.
I need to put on some more miles but this may have resolved the sensation I was feeling; tire must have been hitting on those bumps with the bigger rear tire and softer setting.
Still gonna go for longer shocks if I can find a decent pair for a decent price.  Nothing yet.

Thanks everyone!

Title: Re: Odd (dangerous?) sensation hitting bumps at sp
Post by old.indian on 06/16/16 at 11:46:00

It took me a while before I found the ones I got....    
Don't forget that with the new front pulley, the speedometer is off, as is the odometer .  

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