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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> The Project: Phase 3 /cgi-bin/YaBB.pl?num=1304184759 Message started by MotoBuddha on 04/30/11 at 10:32:39 |
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Title: The Project: Phase 3 Post by MotoBuddha on 04/30/11 at 10:32:39 So, at the end of the Phase 2 thread, some of the Ryca parts had been delivered. http://i280.photobucket.com/albums/kk182/motobuddha/a7289ff0.jpg Soon after, I took the battery box, seat plate, gauge brackets and taillight bracket to the powdercoater. He's backed up, so it will be a while before he can get to it. Last night I took the tank to my painter buddy and discussed what needed to be done and how I'd like to be as involved as possible. There are some dings to fill where the PO let the badly positioned windscreen mounting hardware hit the tank. And another ding was from a fall. These are no big deal, just standard bodywork. The bigger deal is replacing the whole gas cap with a standard old, twist on/off, non-locking cap. http://i280.photobucket.com/albums/kk182/motobuddha/00318241.jpg I'm doing this because I don't like the stock cap, and I don't need a lock. I originally thought about a flush cap, but after looking at them, the openings were smaller than I want. I like to be able to watch the gas level when I fill up. So the first step is to remove the stock filler neck then weld in the new one and pressure test it. That will happen when we can arrange a time when the two of us and his friend with the TIG welder are available. I will document the process. Later today, another friend is coming over to help me put the engine temporarily in the frame so I can test fit the chain drive/swingarm/rearset bracket clearance. I will document that, too. Meanwhile, I have some homemade tacos to eat. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 04/30/11 at 10:43:18 How much more gas does hat tank hold? I am agreeing with you on the gas cap. I like what you got, |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 04/30/11 at 11:03:30 It holds less gas since about an inch of the bottom was cut off http://i280.photobucket.com/albums/kk182/motobuddha/35a38e4f.jpg I don't know the exact volume. But this bike will just be for scooting around town, not long rides. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 04/30/11 at 13:35:40 I saw it as wider, since it looked shorter,, I didnt realiz, it looks a bit shorter, cuz it IS!,,, :) |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 04/30/11 at 13:52:12 My friend, Doug, rode over on his Bonneville to be a second set of hands in getting the engine back in the frame. http://i280.photobucket.com/albums/kk182/motobuddha/b905f9ff.jpg I have a 17 tooth sprocket in front and a 43 tooth in the rear—for now. With the suspension at full extension (no load) the chain just kisses the swingarm at the weld bead. Meanwhile, there's about a chain thickness between the chain and the bottom of the rearset mount (maybe less with the chain properly tightened). UPDATE: With the chain tightened, the chain no longer touches the swingarm. There's about a 1/16" gap. Chain slap might make it touch once in a while. Meanwhile, the gap between the chain and rearset mount is reduced to about 1/4", meaning the notch will be very necessary. http://i280.photobucket.com/albums/kk182/motobuddha/daf8e4c0.jpg http://i280.photobucket.com/albums/kk182/motobuddha/78f5030f.jpg http://i280.photobucket.com/albums/kk182/motobuddha/c2678930.jpg With a load on the bike, the chain wouldn't touch the swingarm but would probably touch the rearset mount. So my plan is to notch the rearset mount and grind a bit off the swingarm. I might also go up to an 18 tooth front sprocket with a 45 in the rear. Oh, and this is with my 12.5" YSS shocks. Your results may vary with different shocks. |
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Title: Re: The Project: Phase 3 Post by verslagen1 on 04/30/11 at 15:51:39 I sure hate to do work twice, or work that didn't need to be done. I'd get the rest of it built up and see how it goes. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/01/11 at 12:59:05 thanks for the photos. this is good to know! |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/02/11 at 16:32:34 Some work with my angle grinder and a file and I have a notch in the rearset bracket for chain clearance. http://i280.photobucket.com/albums/kk182/motobuddha/05278567.jpg http://i280.photobucket.com/albums/kk182/motobuddha/0bcd0980.jpg The clearance you see is with the swingarm pivoted up equal to the travel distance of the shock, as shown here. http://i280.photobucket.com/albums/kk182/motobuddha/dad475a1.jpg I added a little extra room for chain slap. I'll box it in, with the filler pieces recessed into the cut to preserve the same amount of clearance. Even without the boxing, I think there's still plenty of meat left in that section of the bracket. http://i280.photobucket.com/albums/kk182/motobuddha/905bb261.jpg |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/02/11 at 17:20:21 this looks great and appears all that is really needed to fix the issue |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/02/11 at 17:44:07 While fiddling around with the stuff above, I discovered an additional place to squeeze in a second horn (because two horns of different pitches are irritating and get attention better). It's the space where the stock exhaust bracket/emissions canister/jacking point thing would be. Part of the Ryca rearset bracket passes through that area. As long as I'm welding up the notch I made, I could weld a tab onto the bar and drill a hole for the horn. In fact, I might be able to fit both horns down there. If not, the other can go in the tail section. If you still have the stock exhaust bracket and don't have the emissions canister, you could just drill a hole in it. It would look better than that thing hanging on the front. |
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Title: Re: The Project: Phase 3 Post by BurnPgh on 05/02/11 at 21:48:00 just a thought....while you've got everything apart you might ought to drill and tap a hole for a grease fitting on the swingarm. After finding my swingarm bent and the bearings pretty much seized I dont intend to 'uck with them again. Same goes for the stem. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/03/11 at 04:40:15 I'm trying to remember the details of an XS650 build where the guy installed a grease zerk on the steering head. I think he added something like a PVC sleeve on the spindle to reduce the volume of grease needed to fill the head. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/05/11 at 22:41:29 Got a call just before I left for Mexico. The first load of powdercoating that was supposed to take 1.5 weeks are done already. But the guy is a couple of cities over, so it'll have to wait until I get back. Then I'll drop off the frame. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/06/11 at 01:28:07 07253E25083F2E2E222B4A0 wrote:
what body work did you do to the swing arm? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/07/11 at 14:17:52 Cut off and/or ground down the unneeded tabs for the belt guards, etc. I'm still going to take a little off the left pivot for chain clearance. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/07/11 at 14:24:24 6D4F544F625544444841200 wrote:
Did you remove and fill the holes for the rear pegs? |
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Title: Re: The Project: Phase 3 Post by sbaugz on 05/08/11 at 04:25:51 http://www.aerostich.com/catalog/product/view/id/247?gclid=CPTgr4if2KgCFUhrKgodLCHrEg buddha, i remember on your previous post that you were adding a second horn. You sshould check out the horn on the link above. Dubbed as the world's loudest motorcycle horn, this might do the trick. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/09/11 at 08:44:38 59464B4B424D464F475C5D5A5B405A402E0 wrote:
Did you remove and fill the holes for the rear pegs?[/quote] I groundoff and filled in the left one but haven't touched the other because, at the time, I didn't know if it it's needed to anchor the looped around brake light cable. I need to find out. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/09/11 at 08:49:13 7F6E6D796B760C0 wrote:
I've read about some reliability problems with those. It might have been only one production run or something. Meanwhile, my 2-horn setup has worked fine. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/09/11 at 10:55:56 587A617A576071717D74150 wrote:
Did you remove and fill the holes for the rear pegs?[/quote] I groundoff and filled in the left one but haven't touched the other because, at the time, I didn't know if it it's needed to anchor the looped around brake light cable. I need to find out. [/quote] ya by the photos it looks like the right one is in use what color are you painting your frame? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/09/11 at 11:34:34 You'll just have to wait. I'm not 100% sure myself. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/11/11 at 14:37:01 looks like the hole on the swing arm (right side) does get used http://i1226.photobucket.com/albums/ee419/rpnsht/4949359295_f21280c347.jpg |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/13/11 at 16:14:32 Another thread got me thinking about the fork lock. Since I'm having the frame powdercoated, the lock would just cause more trouble than it's worth to me. So I cut it off -- with the lock still in place. Not the fastest way, but viscerally gratifying. http://i280.photobucket.com/albums/kk182/motobuddha/124e8f63.jpg Then I found a bolt that was almost exactly the same diameter as the lock hole. I cut the bolt, leaving about 1/4" of threads. Then I used some JB Weld to hold it in place and fill the lock slot. http://i280.photobucket.com/albums/kk182/motobuddha/d63f2d74.jpg Media blasting should cleanup things. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/13/11 at 16:16:47 Earlier I mentioned grinding a bit off the top of the swingarm for chain clearance. Here it is. http://i280.photobucket.com/albums/kk182/motobuddha/3c07a69f.jpg |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/14/11 at 10:18:25 Spent the morning with the pneumatic spinning thing and a ScotchBrite wheel cleaning 15 years of crud and corrosion from various nuts and bolts. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 05/14/11 at 11:51:02 There was a guy I knew, back in Odessa. He'd buy older cars that needed some TLC & hed drive them & buff them up some,, park them a while & do a few things, till he got them looking Juuust right,, then, he would invariably get drunk & crash them. The last one I saw him do, I went to hang out & I mentioned to him that he shouldnt fix this one up all the way,, & he said Why Not>?? & I said Cuz every time you get one all nice & spiffy lookin, you crash it.. & he said Ohh, Im not gonna let that happen this time. A week later, it was a crumpled up mess & he decided it was MY fault,, & he thot he was gonna come down & whup my butt,,, he calmed down a good bit when he saw my hand go into my back pocket, where I carried a Puma Game Warden,, In fact, he didnt even say G'bye, he just turned & went walkin back to his place, |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/14/11 at 13:42:06 I drink maybe a couple of beers a week, so if I crash this, it won't be because I was drunk. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 05/14/11 at 14:01:44 Ouch~! Sorry if I left that as even a [possible,, First, I Dont expect you to crash it, ever, & B Im sure no one here is goofy enough to ride drunk,, I was just looking at all the TLC youre dumping into that project & I just remembered thaat guy.. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/14/11 at 14:25:39 Crashing is always a possibility. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/14/11 at 15:03:14 233C3A3D20271626162E3C307B490 wrote:
this is what i carry http://www.thebladeshop.com/Benchmade_Mini_Stryker_9500SBK_Auto_p/bm9500sbk.htm |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/14/11 at 16:19:42 Soaking some parts in rust remover. Ooooo, magic! http://i280.photobucket.com/albums/kk182/motobuddha/43168c1e.jpg |
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Title: Re: The Project: Phase 3 Post by sbaugz on 05/14/11 at 16:27:52 76544F54794E5F5F535A3B0 wrote:
what product do you use? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/14/11 at 17:10:29 Evapo-Rust. Found it at Pep Boys. |
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Title: Re: The Project: Phase 3 Post by sbaugz on 05/14/11 at 17:21:50 13312A311C2B3A3A363F5E0 wrote:
wow, with a cool name like that I would expect it to work great. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/17/11 at 13:10:20 First parts back from powder coating — the ones that didn't require agonizing over color. Battery box, taillight bracket, seat pan and gauge brackets. Satin black so they sort of disappear in the shadows. http://i280.photobucket.com/albums/kk182/motobuddha/51064870.jpg |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/18/11 at 17:00:32 I never thought I'd be so happy to get a bill. I just got a notice from Ryca that the rest of my parts are ready to ship once they get the last half of the payment. I'm whipping out the credit card. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/18/11 at 23:35:53 517368735E697878747D1C0 wrote:
yes! |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/20/11 at 11:57:03 There were times I thought the world would end before the parts arrived. Well, the loons say the Rapture is tomorrow and UPS says the parts are in transit. We'll see who wins. |
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Title: Re: The Project: Phase 3 Post by sbaugz on 05/20/11 at 19:10:15 i hear ya |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 13:50:08 Ordinarily my stuff is delivered by The World's Most Cheerful UPS Guy®, who always knocks and we chat a few seconds. But it must have been a different driver today, because he dumped and ran. I'm ten feet from the door all day, so I would have heard a knock. Maybe he didn't want to talk to me because the box from Ryca arrived looking like this: http://i280.photobucket.com/albums/kk182/motobuddha/71727383.jpg The main problem is that whomever did up the box at Ryca didn't tape one side of the bottom. The top flap was tripple taped, but... When I opened the first flap, there was a small baggie with one bolt in it, as if someone had gone, "Oh crap, I forgot this one," and tossed it in the box. The goodies were packed in a combination of air bags and foam peanuts. Okay, fish out the air bags first, then feel around in the peanuts. Some boxes, some bags, and the rear wheel assembly. Did I get everything? http://i280.photobucket.com/albums/kk182/motobuddha/3abbb094.jpg The two small boxes are the gauges, the long one is the muffler. Then there's a parts list, the rear-sets, the grips, the muffler adapter, and a bundle of parts I haven't opened yet. In front of them are the decompression rod and rear brake rod, Ryca stickers, and the extended speedo cable. I guess I know how I'll be amusing myself this long weekend. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 05/25/11 at 14:01:20 so tight! |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 14:29:06 Each of the fasteners and other small bits come in individual baggies labeled with a name, number and picture. This info matches the parts list. I haven't seen attention to detail like this from big, well-established companies, much less a small start-up like Ryca. I can see why things took a little longer than everyone hoped. It wasn't a matter of just welding up a few parts. Bravo! http://i280.photobucket.com/albums/kk182/motobuddha/72845ea2.jpg In case you were wondering about the jets included in the kit, here they are. Man, my old man eyes are going to need a macroscope to read these. http://i280.photobucket.com/albums/kk182/motobuddha/d8e913c3.jpg http://i280.photobucket.com/albums/kk182/motobuddha/4dd58007.jpg |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 14:53:09 I did a finger-tight assembly of the rear-sets. They are things of beauty. I loves me some knurling. The sleeves that go inside the footpegs even have a turned down section to hold grease. These are very well thought out. http://i280.photobucket.com/albums/kk182/motobuddha/f8fc830e.jpg |
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Title: Re: The Project: Phase 3 Post by ralfyguy on 05/25/11 at 15:38:37 2E0C170C211607070B02630 wrote:
What is that stuff called? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 15:46:28 Evapo-Rust. Found it at Pep Boys. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 15:51:09 Before and after on the end of the grip in order to use bar-end signals. A little work with an X-acto knife and, presto. http://i280.photobucket.com/albums/kk182/motobuddha/ed01229e.jpg |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 16:32:48 Shhhhhhhhh, don't tell anyone. http://i280.photobucket.com/albums/kk182/motobuddha/81d9c12c.jpg |
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Title: Re: The Project: Phase 3 Post by Edgar on 05/25/11 at 16:36:09 ;D ;D ;D |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/25/11 at 16:40:20 Notice the corner of the sticker came turned up to make it easier to remove. |
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Title: Re: The Project: Phase 3 Post by sbaugz on 05/25/11 at 17:39:50 795B405B764150505C55340 wrote:
I think Shhhhhhhhh was the wrong word to post since this muffler will likely be anything but quiet. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/26/11 at 09:36:43 http://i280.photobucket.com/albums/kk182/motobuddha/1078521b.jpg I took apart the muffler Ryca supplies. I believe it's an Emgo. Here's the baffle. http://i280.photobucket.com/albums/kk182/motobuddha/34a15d90.jpg http://i280.photobucket.com/albums/kk182/motobuddha/1978bd4b.jpg http://i280.photobucket.com/albums/kk182/motobuddha/09571958.jpg Not much to it. Perforated tube with a perforated disk about 2/3 of the way along, a bit of thin fiberglass matting held on with wire. Okay. Emgos seem to have a reputation for sounding kind of tinny and harsh. Since it's not a large muffler, there isn't the volume for a deep tone, so I figured I could at least cut some of the metallic harshness by adding more packing. I had some SilentSport packing left over from the other bike. It's meant to be poked into canister style mufflers, between the core and the outer wall, but a disk on the end of the Emgo baffle meant I had to try to wrap it around. http://i280.photobucket.com/albums/kk182/motobuddha/0703fb6d.jpg I don't have any stainless steel wire to tie the packing in place, so it was a test of manual dexterity to hold it and slide-tuck-slide-tuck-slide the thing back into the cone. There's a ring inside the cone that complicates the process. But I got 'er done. http://i280.photobucket.com/albums/kk182/motobuddha/e57f4164.jpg Of course, if I want to be very antisocial, I can pull the baffle altogether. http://i280.photobucket.com/albums/kk182/motobuddha/6af1c750.jpg |
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Title: Re: The Project: Phase 3 Post by BuckHMCC on 05/26/11 at 11:55:24 That's exactly what I wanted to know about the Ryca kit-supplied muffler. Thanks! I'll be doing the same to mine. |
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Title: Re: The Project: Phase 3 Post by CalisOsin on 05/26/11 at 12:18:09 Moto - I'm sure you know this, but your attention to detail is truely awesome. I am very excited to see how your bike turns out, and I have a feeling RYCA is going to want many pictures to help sell their product. Thanks for all the great pictures and progress steps. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/26/11 at 12:45:17 A little more muffler info for Ryca kit guys. They include a short, chromed, angled bit of pipe that serves two purposes. The first is to let you angle the muffer so it clears the swingarm now that it tilts down because of the longer shocks. The other purpose is to accommodate the different diameters of the exhaust pipe and the muffler -- one end of the angled piece is smaller than the other. That means other Emgo mufflers might work. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/26/11 at 14:33:23 Does anyone know if it's okay to grind down this spot weld smack in the mouth of the exhaust pipe? http://i280.photobucket.com/albums/kk182/motobuddha/8b2b94f6.jpg Or is it precisely engineered air flow optimizer? ;D |
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Title: Re: The Project: Phase 3 Post by markbacon on 05/26/11 at 17:15:58 Ah yes, the Emgo shorty megaphone. I had one fitted for quite a while and liked it, but if it's just glass packed the pressure pulses will eat that, power delivery will go ragged/peaky and it will be raise-the-dead loud. I mean seriously, you won't be able to think and god only knows what it's like for anyone behind you. What I did was wrap the core with about 3 layers of stainless mesh with very tightly packed glass outside that - tight enough to need a rubber hammer to get the core all the way in. Note the mesh has to stop short of the internal end of the core to fit within the megaphone taper. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/26/11 at 18:58:32 At least the muffler is simple enough to rework in various ways, if necessary. |
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Title: Re: The Project: Phase 3 Post by Boule’tard on 05/26/11 at 19:41:28 One of the guys on my CRF forum took apart an Emgo, repacked it and sort of made it tuneable with crumb cups, of all things. Yes, the sink accessory. His muffler has the same pre-peeled sticker and everything. ;D http://www.hondacrf230l.com/index.php/topic,483.0.html |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/27/11 at 06:03:43 I imagine the handle on the crumb catcher generates a scavenging vortex for an added 10hp. ;D |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/27/11 at 12:30:26 Hurray! Mr. Lumpy is finally here! http://i280.photobucket.com/albums/kk182/motobuddha/cd61367e.jpg Guess I'll be reassembling the engine this weekend. Now where did I put my torque wrench? |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 05/28/11 at 07:29:57 Stainless wire would ( I suppose) be available from a mechanic at an airport. Id bet I could get a few feet for cheap that way. If aluminum would do it, thats easy. Electric fence wire, the cheap stuff, is usually albumium.. |
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Title: Re: The Project: Phase 3 Post by verslagen1 on 05/28/11 at 09:35:13 795B405B764150505C55340 wrote:
I think it was JOG that cut out the center pipe and left the shell. He'd be the person to ask if it was. |
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Title: Re: The Project: Phase 3 Post by CalisOsin on 05/28/11 at 16:43:09 Moto - when you got that cam, did you have to send in a core part? Also, is there anything special you need to do with that new cam after/during install? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/28/11 at 17:43:37 Yes, you send in your old cam and they re-profile it. I don't think there's anything special on the installation. Just the usual. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 05/29/11 at 01:20:38 It comes w/ Cam Lube & the cam needs ( IIRC) around 15 minutes of low RPM operation to break it in. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/29/11 at 08:46:58 I have things stripped down enough to install the new cam chain. I don't have the slot and hole at the bottom of the case blocked off because I want to give Oldfeller the willies. ;D http://i280.photobucket.com/albums/kk182/motobuddha/4bf1b55a.jpg Here's the new chain soaking in oil. http://i280.photobucket.com/albums/kk182/motobuddha/b5bf1d8c.jpg One question, though. The center of primary drive gear sticks out more on one side than the other. I went through the Clymer manual hoping to learn which way the gear is supposed to go back on. No luck. I'm guessing the side that sticks out more faces inward to give clearance for the cam chain. Yes? No? Beuller? http://i280.photobucket.com/albums/kk182/motobuddha/5aaf8b44.jpg http://i280.photobucket.com/albums/kk182/motobuddha/f72a50f4.jpg |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 05/29/11 at 08:51:12 If you know which way the mating gear goes on its shaft,,, well,, you get the idea. You can also slip it on & see if the cam chain conflicts with the short side inside. Im betting youre right about that tho, Or, you can wait on one of the guys who has been in their engine so many times they just know.. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/29/11 at 08:53:29 I guess the other way to figure it out would be to slip it on, replace the clutch assembly, and see if the two gears align properly. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/29/11 at 09:08:08 And the answer, Ladies and Gentlemen, is: long side facing in, short side facing out. http://i280.photobucket.com/albums/kk182/motobuddha/03ba0a01.jpg |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/29/11 at 11:12:25 So, I needed to tighten the big nut on the clutch assembly. Even though I had a strip of aluminum jammed between the clutch and primary gears, the center shaft wanted to turn because the clutch plates weren't grabbing. No surprise, since the springs and the plate that holds them down were off. Ah, but I had an idea. I found four 1/2" flange nuts in my spare fasteners bin, slipped the spring bolts through them and used them as washers to compress the springs. Presto, the clutch plates grabbed enough to let me torque down the nut. Mmmmm, I love the click the torque wrench makes. http://i280.photobucket.com/albums/kk182/motobuddha/3382a2f7.jpg (Just to be clear, the 1/2" nuts came off once I got the big nut torqued down.) |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 05/29/11 at 14:45:23 If I were you, I wuld give some real thot to having a clutch throwout paddle machined. Factory design is weak, youve made its job harder, look closely at the part, it has a square 90 degree angle near the center, right by the rod that twists it. It is just begging to break, It nees to be out of billet & not cast & it needs a radius where the 90 is. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 05/29/11 at 16:08:32 After sufficient wrestling and swearing at the piston rings, I managed to get the new 97mm piston into the bored out cylinder. It would have helped to have had the proper tool and an extra set of hands. http://i280.photobucket.com/albums/kk182/motobuddha/817cb41f.jpg Tomorrow I'll anneal the copper head gasket and get the head, new cam and the rest of the top end installed. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/01/11 at 16:51:56 Over in the tech section is a discussion about converting to chain drive. When you do that, you need some kind of spacer to compensate for the front sprocket being narrower than the pulley. One guy took a spare sprocket and turned it down. Others used washers they found at the hardware store. Since I don't have a lathe or easy access to one, I went the washer route. The one I found at the hardware store wasn't metric so it was loose on the countershaft. I wouldn't want it to work its way off center and cause a vibration. So I went online and found the correct metric size. In stainless steel, even. Using two makes for the perfect thickness. http://i280.photobucket.com/albums/kk182/motobuddha/161297f3.jpg |
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Title: Re: The Project: Phase 3 Post by thumperclone on 06/01/11 at 17:02:43 6D4F544F625544444841200 wrote:
PLEASE PLEASE post that source!!! |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/01/11 at 18:38:03 3428352D302532232C2F2E25400 wrote:
PLEASE PLEASE post that source!!![/quote] http://suzukisavage.com/cgi-bin/YaBB.pl?num=1306968004 |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/04/11 at 09:18:48 A lot of the mods I'm doing are just about looks. For example, I'm going to powdercoat the carb top, float bowl and the round cover thing on the side. But I wondered what the round cover thing is, what's under it and what it does. I checked the manual. Transient enrichment valve, huh? Looks like it moves in and out with the choke knob. Or should that be "transient enrichment knob?" Anyway, it looked like removing the cover was no big deal. Just watch for the spring. Well, it wasn't pretty under there. http://i280.photobucket.com/albums/kk182/motobuddha/48dd2968.jpg http://i280.photobucket.com/albums/kk182/motobuddha/86375c50.jpg http://i280.photobucket.com/albums/kk182/motobuddha/50433d5a.jpg I couldn't help wondering how the sediment and debris would affect carb function. To be safe, I ordered a new diaphragm assembly. Then I got wondering how many other people's fueling problems -- stumbling, backfire, stalling, etc. -- might be related to messed up transient enrichment valves, particularly if they've tried everything else. |
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Title: Re: The Project: Phase 3 Post by verslagen1 on 06/04/11 at 09:27:57 more commonly known as the air cut off valve. needs to be cleaned for sure. and yes, can cause some of the backfires. one of the mod's is too get a softer spring. but I'd only look into it if you couldn't fix it any other way. |
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Title: Re: The Project: Phase 3 Post by ralfyguy on 06/04/11 at 10:21:39 I tried to get this apart the other day, but I couldn't get the screws to budge. >:( Is the screws M4? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/04/11 at 10:40:10 Yes, M4 x 10mm |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/07/11 at 10:47:40 Took the frame and associated parts to the powder coater this morning. The color is a custom order, so it will be a while before it's all done. That's what I get for going with My Little Pony Glitter Princess Ultra Pink® instead of black. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 06/07/11 at 10:59:03 6E4C574C615647474B42230 wrote:
http://i1226.photobucket.com/albums/ee419/rpnsht/XWWX_PONY_Z.jpg |
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Title: Re: The Project: Phase 3 Post by kernel ken on 06/07/11 at 12:53:10 Moto - I like your sense of humor, that was really funny :) Wait...that was a joke, wasn't it ??? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/21/11 at 14:18:22 The special order powder paint color I ordered for the frame finally arrived. They apologized for it taking so long. They'll do a sample in the next day or two to make sure it matches the swatch I ordered from. |
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Title: Re: The Project: Phase 3 Post by Edgar on 06/21/11 at 14:34:59 Can't wait to see yours up and running! |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/22/11 at 08:47:02 Finally got to see a color sample today. I wanted to make sure it matched the color chip. I was apprehensive because even though the chip was a metallic brown/bronze/dark gold color, it's named Atomic Black. Did the chip have the wrong label? No. Everything was fine. http://i280.photobucket.com/albums/kk182/motobuddha/1c0b67a3.jpg So this will be the color for the frame and some other bits. I'll have my painter color match it to use in the graphics. While I was at it, I had the carb top done in wrinkle black. I know, I'll only see a little of it when the bike is assembled, but it pleases my sensibilities. http://i280.photobucket.com/albums/kk182/motobuddha/7c9030a4.jpg |
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Title: Re: The Project: Phase 3 Post by T2 on 06/22/11 at 09:06:27 Nice carb fasteners! ;) Terry |
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Title: Re: The Project: Phase 3 Post by bluesavage218 on 06/22/11 at 16:22:50 Carb looks spiffy!!! I really like that! This gives me ideas!!!!! |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/22/11 at 16:41:01 Now, don't be a copycat. ;D |
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Title: Re: The Project: Phase 3 Post by bluesavage218 on 06/22/11 at 16:46:42 Oh don't worry! I try to be as different as possible haha. I'm thinking painting the little circle and the big circle two different colors.... maybe |
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Title: Re: The Project: Phase 3 Post by Gyrobob on 06/22/11 at 19:37:10 73606D6778667478010 wrote:
ralfyguy, please see reply #62 of the Double Ryca Build. There are some pics there that show a technique we used to get those screws loose without destroying them. You are right!! Those things seemed like they were welded in there. Just use a punch on the side of the head of the screw and tap moderately. AFter several taps, tap on the other side of the screw. Soon you'll see it move a tiny bit,... that means they are "unwelded" enough to use a screwdriver. Good luck! |
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Title: Re: The Project: Phase 3 Post by ralfyguy on 06/22/11 at 20:41:00 0A343F222F222F4D0 wrote:
ralfyguy, please see reply #62 of the Double Ryca Build. There are some pics there that show a technique we used to get those screws loose without destroying them. You are right!! Those things seemed like they were welded in there. Just use a punch on the side of the head of the screw and tap moderately. AFter several taps, tap on the other side of the screw. Soon you'll see it move a tiny bit,... that means they are "unwelded" enough to use a screwdriver. Good luck![/quote] Thanks for the advice, but I got them loose now. I used a "2 phillips screwdriver and ground the tip flat a bit more. That allows the blades to get more connection with the slots. It's not a perfect fit, but it worked with enormous pressure applied. I just pushed my upper body against it, holding the screwdriver with both hands. Then carefully applied pressure to the right and left, alternating a few times and bang, they broke loose. Key is the pressure, to not let the blade cam out. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/22/11 at 21:41:49 This is weird, because I had no problems with any of the carb screws. Maybe the years of neglect made a difference. |
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Title: Re: The Project: Phase 3 Post by RpNSht on 06/23/11 at 01:13:51 paint color is pretty sweet. what type of graphics are you considering? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/24/11 at 09:24:21 Here's my current thinking, subject to change. I designed this logo for the side covers. My initials are AC and I was "established" in 1952. The brown would be the same color as the frame. http://i280.photobucket.com/albums/kk182/motobuddha/1a9e2a87.jpg Here's a very rough mockup of what it will look like on the bike. I'd pick up the dark red for pin striping. http://i280.photobucket.com/albums/kk182/motobuddha/7e4cbd22.jpg |
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Title: Re: The Project: Phase 3 Post by bluesavage218 on 06/24/11 at 09:28:00 Love it!!!! Nice work sir!! That's a really cool logo. |
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Title: Re: The Project: Phase 3 Post by babyhog on 06/24/11 at 09:35:39 I like your color combo choice, and I think the pinstriping would be a perfect touch. The logo is cool. I think alot of folks will ask you what AC means. Definitely agree those side covers need "something" though. One creative dude you are! |
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Title: Re: The Project: Phase 3 Post by buttgoat1 on 06/24/11 at 09:48:18 looks good you have good attention to the little detail items like the carb top |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/24/11 at 11:42:39 Here's another idea. The side cover is about the size of a number plate, so... http://i280.photobucket.com/albums/kk182/motobuddha/07f2925d.jpg 9, because this is my ninth bike -- though here in NASCAR country, they'll think it's for Marcos Ambrose. |
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Title: Re: The Project: Phase 3 Post by bluesavage218 on 06/24/11 at 12:14:42 OOOOHHHHH I'm a number fan! I vote for the number! You could get a matching helmet with number 9 on it. |
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Title: Re: The Project: Phase 3 Post by Edgar on 06/24/11 at 13:28:13 Number on one side, Logo on the other |
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Title: Re: The Project: Phase 3 Post by bluesavage218 on 06/24/11 at 14:05:25 I like that too! or logo on top of tank, numbers on both sides |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/24/11 at 18:45:59 I've been trying to figure out a way to supplement the rear turn signals. Even if the integrated lights in the kit pass inspection, I'd rather have something further from center. The bar-end signals I'll use face front and rear, but I think they might be at least partially blocked by my arms or torso. If the license plate didn't need to be nearly horizontal, I could use a frame with built-in signals. I could make one of those brackets that bolts on the back of the license plate to hold any sort of aftermarket signals, but the trick is to do it in a way that hides all the bolts and wires, since you'll see the bottom of the plate pretty much edge on. It would be cool if I had the engineering and fab skills to make signals that tucked under the tail but flipped down and outward when needed. I've thought about molding LED strips along the bottom of the tail, or even cutting channels so they could be molded flush. Or maybe the same general idea along the back edge of the side covers. I don't know. I'm leaning toward mounting small super bright lights to the bottom back edge of the seat pan, or the battery box, or somewhere in the general area. I'll be able to figure out more once I get the frame back and I can start putting things together. |
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Title: Re: The Project: Phase 3 Post by T2 on 06/24/11 at 18:46:21 Number plate is awesome. What we really need to do is get rid of the side stand extensions/ wood block, cinder block, whatever. Do they really lean over that far? If so, my running leap onto the saddle as I escape the crime scene is gonna be problematic. Terry |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/24/11 at 18:55:23 I'm not too thrilled with the way the ignition/idiot light plate mounts to the tank. The rubber trim isn't an attractive solution. I'm going to talk with my painter guy about welding it in place and then filling the joint. Hurray for Bondo. Does anyone know how much of that lip can be cut down without breaking through into the tank? On the other hand, we'd have the welder out, so... |
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Title: Re: The Project: Phase 3 Post by RycaShawn on 06/24/11 at 19:54:18 44667D664B7C6D6D6168090 wrote:
Haa! Already thought about that too. Gotta figure out how to pressure test the tank after welding before any bondo action. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 06/25/11 at 02:49:29 Fold the metal over? Hafta do some cutting in th curved spots, but a bit of brazing would solve that.. BUT,, Ill let someone else get a gas tank hot,, Im a chikkin.. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/25/11 at 04:38:07 Well, the tank has had extensive welding done on it for the Ryca mod. If it were going to blow up it would have already. |
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Title: Re: The Project: Phase 3 Post by justin_o_guy2 on 06/25/11 at 08:42:15 Have you put gas in it since its been on? |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/25/11 at 09:20:47 No. The tank went from Ryca to me to my painter, where it's awaiting some bodywork, de-rusting, sealing and such. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/29/11 at 13:08:02 The powdercoater called. My stuff is ready -- just in time for the long weekend. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 06/30/11 at 09:25:43 I picked up the frame. http://i280.photobucket.com/albums/kk182/motobuddha/194ac321.jpg http://i280.photobucket.com/albums/kk182/motobuddha/62165319.jpg Along with some other pieces. For example: http://i280.photobucket.com/albums/kk182/motobuddha/4c74e3e3.jpg The color is actually darker in real life. The powder coater did an excellent job masking off parts like the steering and swingarm bearings and all the holes. I won't be spending the rest of my life scraping powder coat from unwanted places. |
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Title: Re: The Project: Phase 3 Post by sbaugz on 06/30/11 at 09:52:04 looks real good. can't wait to see it done |
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Title: Re: The Project: Phase 3 Post by RpNSht on 06/30/11 at 10:36:57 002239220F382929252C4D0 wrote:
lucky. your powder coater should talk to mine and teach him how to mask properly |
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Title: Re: The Project: Phase 3 Post by sbaugz on 06/30/11 at 11:25:58 no kidding on the masking. my powder coater didn't mask very well either and I broke off a bolt in the oil filter cover on my clutch cover. had to have the hole plugged and re-tapped. |
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Title: Re: The Project: Phase 3 Post by MotoBuddha on 07/02/11 at 09:07:49 Continued on The Project: Part 4 |
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