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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> My $40 Savage /cgi-bin/YaBB.pl?num=1529202769 Message started by magnum440d100 on 06/16/18 at 19:32:24 |
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Title: My $40 Savage Post by magnum440d100 on 06/16/18 at 19:32:24 Whaddup guys and Gals! I just wanted to share my latest project I saved from the scrap heap. A friend of my friend did some property cleanup and received this bike as partial payment. So, he decided to scrap it (reason in the next reply, since it appears that I can only post one pic at a time). So here's a pic from the day I went to pic her up. As you can see, there are jumper wires leading to the battery terminals. This is important because they tried to crank the bike, which it would not crank, which is why it was destined for the scrap pile. |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/16/18 at 19:35:36 This being the reason why it was going to the scrap heap. Someone somewhere at some time, pulled the starter idler gear out. So when the bike cranked, only the starter spun. The guy I got it from ran jumper wires, and when the bike didn't crank, he decided to scrap it! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/16/18 at 19:43:10 Ordered the gear. It was on back order, with no arrival date in the near future. But the shop called me yesterday that it came in, so today I went and picked it up. The bike now cranks with the button pushed and clutch pulled. There is still TONS to do. Carb rebuild, forks need resealed, plus lots of little things. But now that it cranks like it is supposed to, I'm comfortable putting money into it. Next paycheck, I'm getting the carb rebuild kit, and side cover (starter side) gasket. Then oil change, and see if she pops..... Stay tuned kids! And if anyone has any advice, or suggestions, please let me know. Don't be shy! |
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Title: Re: My $40 Savage Post by LANCER on 06/17/18 at 04:07:33 Way to go ! They are rarely really dead. |
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Title: Re: My $40 Savage Post by Dave on 06/17/18 at 04:11:02 There should be a flat washer on both sides of the torque limiting starter gear. The washers prevent the splined shaft from digging into the aluminum case and cover. You photo doesn't show a washer on the outside of the gear......do you put one on after you took the picture? |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/17/18 at 10:05:03 49727F6879756E68737B76691A0 wrote:
Good catch! No I did not install a flat washer, as I was unaware that one was required. I purchased a Clymer manual from the local motorcycle shop, and it shows the manual is for 86-88 or there abouts. It did not specify a washer. But I was reading through Sad Savage's thread and downloaded the Clymer through the link provided there which goes up to 2004. I have not had a chance to read through it yet though. Fortunately, the side cover is not fully installed yet. Just on there to make sure that the motor cranks. I still have to order the gasket before I can permanently install it. Again, THANK YOU for catching that! |
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Title: Re: My $40 Savage Post by batman on 06/17/18 at 17:28:00 I wouldn't be turning the bike over without adding some oil/fogging oil into the cylinder through the spark plug hole ,you could cause damage to the rings and cylinder walls ,as they have no lubrication until the bike actually runs. If the wires I see in the first pic is what they used to try and jump the bike, it wouldn't have turned over anyway ,they're much to small to carry enough power to turn the starter under load. No washers should be installed on either side of the gear your replacing ,that would jam the gear train when you put the side cover back on. It may be good to use a volt/ohm meter and check the stater( it's in the Clymer's) before replacing the sidecover. |
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Title: Re: My $40 Savage Post by josesito on 06/19/18 at 14:03:39 Have you considered going to a friend of yours or trusted motorcycle mechanic to help you out? I know fixing a bike can seem exciting but you might consider asking someone for advice first as motorcycles are composed by many parts that work at pair. Just my two cents here. Also buy the clymer manual so you can see if you are missing any other parts. |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/19/18 at 19:33:36 47445148444B111D250 wrote:
Sorry for the late response. Work keeps me busy haha Good call on fogging the piston/cylinder with oil. I did that the day I purchased it, knowing I wouldn't be able to work on it again for a few days/week per my work schedule. So, NO flat washer required? 10-4! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/19/18 at 19:37:17 53564A5C4A504D56390 wrote:
New to Savages but not motorcycles. My last bike was a 1978 Yamaha XS 750 triple. I should have never gotten rid of that bike! Clymer has been purchased last week, as well as downloaded through the link in Sad Savages thread. |
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Title: Re: My $40 Savage Post by Dave on 06/20/18 at 04:26:48 636F69607B633A3A3E6A3F3E3E0E0 wrote:
The rear idle gear that is closest to the starter motor does not get any washers. The other idler gear that has the splined shaft and the torgue limiter requires a flat washer on both sides (inner/outer). |
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Title: Re: My $40 Savage Post by Tocsik on 06/20/18 at 06:53:05 So glad you knew about oiling the cylinder before trying to move the piston. That one had me worried when you described that you were cranking it around with the starter already. Good luck with the project! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 14:43:48 08333F2F35375C0 wrote:
Yeah, I've brought many engines back from the dead, that people have given up on. I usually oil em up and let them soak for a week minimum if I can. sometimes it is only a few days, but hey, it's something! Thanks for the luck! Seems I'll need it on this one! haha |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 14:50:38 I threw out my back at work yesterday, so not much progress on the Savage. Although I DID remember I had an ultrasonic cleaner I could drop the carb and parts in and hobble away and come back to after while... So, on the chopping block today is the carb! I can't get a kit till Monday, so I thought I'd let her soak and clean over the next day or so. I will pull the parts out and dry, then do another run. I wont be leaving the parts in the cleaning solution, since the carb and parts are aluminum. So here she is pre tear down! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 14:52:57 Got the bowl off.... Glad I'm going the ultrasonic route, and not just a can of GumOut!! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 14:56:54 After one round in the cleaner. I couldn't get the screw out due to a LOT of crud. After the first go around, I was able to remove that screw for a better clean... |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 15:00:42 The project was almost over before it began! Someone attempted to remove this screw before and just about stripped the head! Luckily a pair of vice grips grabbed the head JUST right and I was able to break it free. The alternative would NOT have been pretty! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 15:03:46 I am absolutely blessed that the diaphram is in great condition!! I may not need a kit right away. Maybe a thorough cleaning will do wonders! (I can hope, right?? HAHA) |
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Title: Re: My $40 Savage Post by batman on 06/20/18 at 19:24:56 Be aware that rebuild kits bought on line often come with jets of the wrong size,(smaller) the stock jets for the Savage are 52,5 pilot 147 main. |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 19:53:46 62595443525E454358505D42310 wrote:
The rear idle gear that is closest to the starter motor does not get any washers. The other idler gear that has the splined shaft and the torgue limiter requires a flat washer on both sides (inner/outer). [/quote] I've now read 2 versions of the Clymer (print and digital) and there is no mention of a washer. If it is supposed to be there, I WANT to put it back on. Do you have any part numbers or links to said washer(s)? Hopefully this doesn't come across as rude, as it is not meant to be. I am genuinely curious! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 20:01:40 4447524B4748121E260 wrote:
Good info, Thanks! Is there a preferred kit or manufacturer? I was just going to go to the local cycle shop and purchase there, but if there's a tried and true brand that can be had more economically, that would be ideal. I'm still trying to stick to a $500 budget! Just a personal goal, not wholly necessary though haha Speaking of budget, here's where I'm at: Bike: $40 Battery: $100 Starter Gear: $50 Clymer: $30 So $180 into my $500 budget (not counting purchase price) leaves me $320........ |
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Title: Re: My $40 Savage Post by batman on 06/20/18 at 20:49:38 washers (2) one on each side of the torque limiting gear (the gear with three sets of teeth) Suzuki part number 09181-10167 (about $1.30 each) |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/20/18 at 21:02:23 3E3D28313D3268645C0 wrote:
That is amazing, Thank You! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/21/18 at 00:39:01 Last question of the night, I promise haha. so, I've got the carb torn down fairly far and I've been running it in the ultrasonic. I ran it a couple times to facilitate easier disassembly, due to how much crud there was. So, I'm down to everything off besides the floats and needle. I cannot seem to get the float pin off/out. In the Clymer, it says to "Remove pin" to take off the floats. but it doesn't show HOW to remove the pin! I've tried a drift and tapping from the small side towards the big side, I've tried getting something behind the big end and prying slightly, I've tried both at the same time even! It will NOT budge!!! I'm ASSUMING that it's just pressed in there. And I'm ASSUMING that it's stuck in there due to the amount of crud that was in the bowl. Maybe it rusted (or oxidized, if you will) and is seized to the aluminum??? What am I missing?!?!?!?! |
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Title: Re: My $40 Savage Post by Dave on 06/21/18 at 03:13:21 2824222B302871717521747575450 wrote:
The rear idle gear that is closest to the starter motor does not get any washers. The other idler gear that has the splined shaft and the torgue limiter requires a flat washer on both sides (inner/outer). [/quote] I've now read 2 versions of the Clymer (print and digital) and there is no mention of a washer. If it is supposed to be there, I WANT to put it back on. Do you have any part numbers or links to said washer(s)? Hopefully this doesn't come across as rude, as it is not meant to be. I am genuinely curious! [/quote] The Clymers manual was written and photographed using an early version of the bike that did not have a torque limiter gear. Using an onlne parts diagram is very often a good way to see where things go......the part number....and what the parts cost. https://www.bikebandit.com/oem-parts/2014-suzuki-boulevard-s40-ls650/o/m156497#sch869712 |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/21/18 at 14:07:09 I think the carb killed my ultrasonic cleaner! Hahaha After running it through a couple times, here's what the cleaning solution looked like... It's supposed to be yellow/yellow green.... |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/21/18 at 14:11:09 Not sure what all that crap is, but its what was left on the bottom of the tank of the ultrasonic cleaner..... This was fresh cleaning solution put in just before the carb... Whatever it is, my ultrasonic stopped working. I put fresh solution in, and now heat doesn't work anymore, and the cleaner runs only for a few seconds before it flashes E01 and shuts off...... I've unplugged it, and I'm going to let it sit for a bit and plug it back in... Hopefully its something simple.... But the carb came out SPARKLING!!! |
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Title: Re: My $40 Savage Post by batman on 06/21/18 at 14:27:28 Your correct in thinking that the pin is only pressed in and that it only comes out in one direction , be careful of how much force you use the carb body is just pot metal. the best penetrating oil ever tested was a 50/50 mix of acetone- (fingernail polish remover), and ATF . you cold apply this to the pin area a few times,( the acetone evaporates quickly) and then try pressure. good luck! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/21/18 at 18:44:26 AAAAANNNNNNNND then this happened. Or maybe it already was bad.... Got the bike to pop once, and then nothing. Just a super fast crank... Been there before, and knew what it was.... SO, on top of the list of things to do, now is the timing chain... My only concern at this point is whether this engine is an interference or not...... ugh.... |
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Title: Re: My $40 Savage Post by Dave on 06/21/18 at 18:59:21 Things are close enough that it is an interference fit - however I suspect that with only 1 bang.....nothing was spinning fast enough to create a condition where the valves were open when the piston came up to the top. The only way I can think to check - is to either take the head off and look, or to put it back together and do a compression test to see if the valves still seal. |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/21/18 at 19:03:50 Is it possible to put in a new chain without removing the head? I haven't had a chance to look in the Clymers yet, as I cannot work on the bike until next weekend (A week from this coming up Saturday)... EDIT: I had a chance to look through the Clymers.... Easier than I thought! |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/21/18 at 23:37:07 I got caught up in the timing chain dilemma and forgot to post my carb after it had been ultrasonically cleaned... This is after assembly, and it does not look too bad if I don't say so myself! I had been putting off doing it because I imagined a horrible mess (I was right) and I imagined a BUNCH of spray carb cleaner. I totally forgot I had the ultrasonic... And on THAT note, I unplugged it for a few hours and all seems well. It's probably happy to not be doing a carb haha |
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Title: Re: My $40 Savage Post by Dave on 06/22/18 at 04:51:25 202C2A23382079797D297C7D7D4D0 wrote:
I did this job a month ago, and it doesn't need the head removed. I used one of Lancer's nitrided chains that should last longer than a stock one. It would have been easier to get the cam/cam sprocket in place if I had removed the bolt that secures the rear chain guide rail....that would have provided a bit more slack in the cam chain. This is a very good time to cure the oil potential oil leaks and retorque the head. Use a Versy head plug, remove the left front and right rear cylinder head stud nuts and washer, clean them up, apply antisieze to the threads and a small amount of Suzukibond to the top and bottom of the copper washers, as those can weep oil (remove the left rear and right front cylinder stud nuts and clean them and use antisieze...the sealer is not necessary on the copper washers). Remove the cylinder head nuts under the intake and exhaust port, clean them and apply a bit of antisieze on the threads and a small amount of Suzukibond on the shoulder of the nut. |
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Title: Re: My $40 Savage Post by batman on 06/22/18 at 21:51:52 Magmun in the picture of your carb ,is that a solid rubber cap just above and a little to the right of the choke nob? |
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Title: Re: My $40 Savage Post by Dave on 06/23/18 at 03:17:58 5152475E525D070B330 wrote:
I see a carb "implosion" in somebody's future! ;) |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/23/18 at 07:30:17 7172677E727D272B130 wrote:
Yes it is. It got taken off after the pic was taken and carb installed... |
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Title: Re: My $40 Savage Post by magnum440d100 on 06/23/18 at 07:31:35 4E75786F7E72696F747C716E1D0 wrote:
I see a carb "implosion" in somebody's future! ;)[/quote] I took it off after install, after consulting the manual. Previous owner installed it apparently for who knows WHAT reason..... |
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