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Message started by steelwolf on 12/22/06 at 08:15:53

Title: Off beat measurments and sizes
Post by steelwolf on 12/22/06 at 08:15:53

First off please let me ask that this list not be hijacked into a discussion. Comments can be directed to members via private message and they can in turn, modify their posts here if necessary.
I guess I'll go first. I browsed the site for a few of these so thanks to the ones who posted them.

Handlebars...1"

Exhaust header @ muffler end...1.75"OD

Piston diameter...94mm

Fuel line...5/16"

Vaccume line...3/16"

Fork diameter...38mm

Oil drain plug (determined by year)...14mm or 17mm

Overall length...86.2"

Overall width...30.5"

please continue......

Title: Re: Off beat measurments and sizes
Post by serowbot on 12/30/06 at 10:23:12

Front sprocket.... 32mm socket

Rear axle.... 17mm Rtside / 24mm Ltside

Title: Re: Off beat measurments and sizes
Post by thumperclone on 12/31/06 at 09:34:49

idle speed 1k-1.2k rpm
plug gap 0.8-0.9mm (ngk dpr7ea-9)
comp ratio 8.5-1
dry weight 352#,355# calif model
displacement 39.8 cu.in.
got more if needed some are year specific..

Title: Re: Off beat measurments and sizes
Post by steelwolf on 12/31/06 at 10:57:37

Screw sizes....

Carburator Bowl - M5
Floatchamber - M5
The little cover on the RH side of the carb is the
Transient Enrichment Valve - M4

Thanks Kropatchek

Title: Re: Off beat measurments and sizes
Post by steelwolf on 01/18/07 at 18:21:24

Muffler adapter bend is 10 degrees

White spacer thickness = approx. 2.8mm or .111"

Title: Fork cap nut size
Post by franch on 04/30/07 at 02:43:33

fork cap nuts = 27mm

lower fork tube allen bolts = 8mm you need a fairly long one maybe 3-4 inches

Title: Re: Off beat measurments and sizes
Post by verslagen1 on 08/17/07 at 15:14:18

rigidchop wrote:

for future reference on an 87, it's 30 mm for the crank and 32 mm for the clutch. thanks for your help.

Title: Re: Off beat measurments and sizes
Post by drums1 on 06/06/10 at 14:09:48

Anyone know the carb float settings? (height and drop?)

Fuel level 0.256 to 0.296"
Float ht. 1.06 to 1.114 "

Title: Re: Off beat measurments and sizes
Post by youzguyz on 08/08/13 at 08:54:55

Oil Filter O-ring
Copy/Paste from post by HondaLavis before it gets lost in the general mish-mash of the universe
=========================================
Did some looking to compare the dimensions of the stock o-ring to the assortment they had at O'Reilly's. The stock dimensions are 2.4mm thickness, 15.8mm inner diameter. The assorted individual o-rings were all SAE. The closest was 3/32 thickness, 5/8 inner diameter. Translate that to metric, that's a 2.3813mm thickness, and 15.8750mm inner diameter. I can't imagine a couple of hundredths of a MILLIMETER making a huge difference.

For anyone else who needs this O-ring, it should be #114 at O'Reilly's. All said and done, I spent $0.65. And, YES, it will be fine in the oil. Wink

::UPDATE::

I just put it on, and it fits just fine. Nice and tight around the fitting to the filter, and it provides positive pressure when you push the filter against it. Again, to any of you with PO's who lost an o-ring (because none of US have ever lost them, right? Roll Eyes ) here is the $0.65 answer.
Back to top

Title: Re: Off beat measurments and sizes
Post by danjray on 08/12/13 at 06:02:14

The 2 screws holding the slide needle down inside the slide are M3 *~6mm length.

Title: Re: Off beat measurments and sizes
Post by verslagen1 on 01/12/14 at 20:38:19

Valve cover O-rings are -139, fits tight to the outside.
-138 might fit too, but the -139 are self retaining and what I had access too.

Title: Re: Off beat measurments and sizes
Post by MnSpring on 01/06/15 at 17:28:12

32 MM = 1-1/4 SAE

Title: Re: Off beat measurments and sizes
Post by KennyG on 01/22/15 at 13:02:43

Suzuki Factory Risers

Both the Allen bolts in the top of the risers, and the studs coming out of the bottom of the risers are:

10 MM x 1.25 threads This is a finer thread than the common pitch which is 1.5 threads

Kenny G

5378747C6A4D767D7D190 wrote:

On my 2007 S40 the risers are 100 mm apart center to center.

Title: Re: Off beat measurments and sizes
Post by Dave on 01/28/15 at 05:00:19

The thread size and pitch for the carb idle fuel mixture is a 6.0mm x 0.50. This is a very fine pitch....taps are available in this size, and you may need to use one if the carb body is corroded and the screw is too tight. The screw should move in/out easily.

Title: Re: Off beat measurments and sizes
Post by Jeff71 on 04/11/15 at 12:24:25

I raided ACE today and found the cap to cover the speedo cable hole on the engine. The threads on the engine are actually 16mm-1.5pitch but this cap went on fine.
http://i264.photobucket.com/albums/ii173/mode4eng/20150411_131318_zpsrvts6xxy.jpg (http://s264.photobucket.com/user/mode4eng/media/20150411_131318_zpsrvts6xxy.jpg.html)http://i264.photobucket.com/albums/ii173/mode4eng/20150411_131340_zpsgqwzoru3.jpg (http://s264.photobucket.com/user/mode4eng/media/20150411_131340_zpsgqwzoru3.jpg.html)http://i264.photobucket.com/albums/ii173/mode4eng/20150411_140445_zpsbc6w3tiy.jpg (http://s264.photobucket.com/user/mode4eng/media/20150411_140445_zpsbc6w3tiy.jpg.html)
A little RTV around the base and things should be sealed right up.
Jeff

Title: Re: Off beat measurments and sizes
Post by verslagen1 on 10/02/16 at 22:32:39

Exhaust header bolt
M8x1.25x35

Title: Re: Off beat measurments and sizes
Post by Kenny G on 11/19/16 at 16:53:25

Spark Plug Wrench

If you do not have the factory tool kit with the spark plug wrench included you will need to find an 18mm Spark Plug Wrench.

Sears has them in stock.

Kenny G

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:05:57

Flywheel nut wrench size = 46mm or 1 13/16" deep socket

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:09:36

Countershaft Pulley seal size = 36 x 50 x 6 (millimeters)

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:10:30

Decompressor shaft seal size = 10 x 20 x 6 (millimeters)

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:15:09

Drain Bolt Thread = M12 x 1.25
Same thread as the spark plug

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:15:51

Oil fill cap thread = M20 x 1.5

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:18:33

Shift Shaft Seal = 12 x 22 x 8 (millimeters)

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:26:55

Crank end seal (in right cover) = 16 x 30 x 6 (millimeters)

Title: Re: Off beat measurments and sizes
Post by DG on 05/09/17 at 11:29:24

Front pulley (sprocket) nut size = 32mm or 1.2598" , 1 1/4" socket will often fit.

Title: Re: Off beat measurments and sizes
Post by DG on 05/11/17 at 18:46:50

Alternator key: Radius into crank = 10mm, Thickness = 5mm exactly, Height with full 10mm radius = 7.5mm
If making one, use strong, but not hardened steel - you want the key to fail rather than destroying the crank.
Turn the stock to 20mm diameter. Cut off at a bit over 5 mm thick. File, sand and/or stone to the 5mm thickness - should be a snug fit in the crank. Saw off at ~8mm and file/grind/belt sand in the 7.5 mm height. Break all edges and you are done.
I found the lost one 5 minutes after making one.....

Title: Re: Off beat measurments and sizes
Post by verslagen1 on 11/10/17 at 17:46:53

valve timing

Title: Re: Off beat measurments and sizes
Post by verslagen1 on 03/27/18 at 10:32:32

4E4A4F4A4B4056250 wrote:

I've only found this:

The rpm at which the engine gets "happy" can be predicted by the closing point (angle) of the intake valves. The angle is expressed as the number of degrees After Bottom Dead Center (ABDC) that the valves reach .053" from being fully seated.

30 degrees = 2400 rpm
35 degrees = 3000 rpm
40 degrees = 3600 rpm
45 degrees = 4000 rpm
50+ degrees = 4500 rpm

These relationships are approximate but should hold true to within 200 rpm or so. They also assume that all other tuning factors, exhaust, ignition, etc., are operating correctly.

If you have one of the late-closing cam designs installed, say one that closes the intake valves later than 40 degrees, then you cannot expect excellent performance at 2000 rpm. No carburetor adjustment, ignition adjustment or exhaust system can change this.

LS650 stock
Int Open 22 BTDC
Int Close 59 ABDC
Exh Open 64 BBDC
Exh Close 14 ATDC
Lift: 0.254" In / 0.244" Ex
Duration: 224° @ 0.050" lift

DR650
Int Open 9.5 BTDC
Int Close 47.5 ABDC
Exh Open 51.5 BBDC
Exh Close 9.5 ATDC
Lift: 0.364" In / 0.367" Ex
Duration: 237° @ 0.040" lift

Title: Re: Off beat measurments and sizes
Post by zipidachimp on 03/27/18 at 18:53:50

Weight: 140/90-15 tire and wheel... 31.3 lbs. 8-)
kenda challenger

Title: Re: Off beat measurments and sizes
Post by madmikesmech on 05/27/19 at 13:51:20

3A3D2C2C253E26252F490 wrote:

Screw sizes....

Carburator Bowl - M5
Floatchamber - M5
The little cover on the RH side of the carb is the
Transient Enrichment Valve - M4
How about the needle retainer screws in the slide?
Oh love that sticker on your keyboard!!! Where do you get them?

Thanks Kropatchek

Title: Re: Off beat measurments and sizes
Post by youzguyz on 01/22/20 at 13:52:19

Spoke torque (as per Verslagen1)
3.5ft-lb (front and rear)
If your spoke torque wrench uses in-lb, then 42 of those
If it uses n-m, then 3.95 of those.

later years went to 3.7 ft-lb

Title: Re: Off beat measurments and sizes
Post by verslagen1 on 10/18/22 at 19:57:10

3F3338500 wrote:

Updating this thread in case anyone ever runs into the same trouble, since I myself discovered it 15 years after the original post.

For my 2013 S40 the hole in the housing and the starter insert are different sizes than the original posters, which isn't surprising. The Savage went through some revisions, including new gearbox, torque limiting gear for the starter, etc - so depending on the year the sizes of the o-rings may differ. But for my 2013 I ordered three different sizes of O-rings to experiment with.

35mm ID x 3mm x 41mm OD - McMaster part 9262K293
35mm ID x 3.5mm x 42mm OD - McMaster part 1302N604
35mm ID x 4mm x 43mm OD - McMaster part 9262K354

I started with the biggest one, the 43mm, and it was just too tight. Went down the size to 42mm, and it fit nicely, very snug - had to lightly tap the starter in with a hammer to get it to go.

These rings are sold in packages of 25pcs, so I still have 24 left, if anyone ever runs into the same problem, let me know and I'll mail you one.

The closes US size would be 1-3/8" ID x 1/8" x 1-5/8" OD