|
SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> The Project: Phase 4 /cgi-bin/YaBB.pl?num=1309622696 Message started by MotoBuddha on 07/02/11 at 09:04:56 |
|
Title: The Project: Phase 4 Post by MotoBuddha on 07/02/11 at 09:04:56 Okay, it's reassembly time, which should be the last phase of this project. This morning I got the front and rear ends installed -- a tricky thing to do singlehanded. http://i280.photobucket.com/albums/kk182/motobuddha/53f2ce90.jpg I had a hard time getting the rear brake back together. The new shoes were binding on the drum. So I got out the flat file and wore away a few hundred miles of brake material. I encountered one small powder coat issue. One shock mount hole on the swingarm had a little buildup on the lip. The stepped bit took care of that in a couple of seconds. Where I started: http://i280.photobucket.com/albums/kk182/motobuddha/49d4ca3c.jpg |
|
Title: Re: The Project: Phase 4 Post by Abbey Normal on 07/02/11 at 09:29:17 Looking outstanding! |
|
Title: Re: The Project: Phase 4 Post by SuperSavage on 07/02/11 at 10:57:31 MB, you've got the Midas touch! |
|
Title: Re: The Project: Phase 4 Post by ralfyguy on 07/02/11 at 11:03:07 I like those tires. Looks better than those old style looking ones on the RYCA prototype. |
|
Title: Re: The Project: Phase 4 Post by skeebo on 07/02/11 at 11:08:37 Looks great! |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/02/11 at 11:26:40 4A59545E415F4D41380 wrote:
I like the looks, sort of like a cross between dirt track and sportbike tires. They're the ones Ryca provides as standard, if you get them from them. I got the front elsewhere because I went with an 18" front instead of 19". |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/02/11 at 11:35:28 Rats. The threads on the clutch lever perch are stripped. It let go just as it was starting to snug up to the bar. I scrounged a longer bolt from my box since there was a little more hole, but it let go too. My options are to get a new clutch lever perch ($$), or have someone machine a flat recess at the top of the bolt hole so I can use a nut on a longer bolt -- which is the way it should have been done in the first place. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 07/02/11 at 12:11:52 A dremel with a small mill attachment will let you freehand it, Or, if you have a drill press,, buy a drill bit & work the end to do the job or buy an end mill,, not too pricey, be less than hiring it done. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/02/11 at 14:35:20 Here's a little detail. The the caps from my handlebar mounts were rusty, so I had them done the same color as the frame. I don't particularly like the way the socket head bolts stick up, but I haven't had any luck finding button head bolts that are long enough. Oh well. http://i280.photobucket.com/albums/kk182/motobuddha/b03df77c.jpg Maybe next year I'll rework the whole top triple clamp and gauge arrangement. I really only need a speedo anyway. Maybe I can figure a way to implement an old headlight bucket with the speedo mounted in it. |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 07/02/11 at 14:42:43 How about carriage bolts? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/02/11 at 14:48:20 I'd need to cut square holes in the caps. Not impossible. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/02/11 at 15:10:26 I have a temperature gauge I'm thinking of mounting between the tach and speedo. I'd need to find a sender to fit one of the bottom front oil access ports. |
|
Title: Re: The Project: Phase 4 Post by ralfyguy on 07/02/11 at 20:58:11 I got a SS Carriage Bolt at Lowe's to mount my tach with a chrome clamp to the handlebar, just left of the handlebar bracket. Due to the lack of a lathe, I took my cordless drill and stuck the threaded end in the chuck and tightened carefully. Then I put the cordless drill on my front steps, laying it on it's side and holding it down with my left hand and letting it run, I held a file to the square piece on the underside of the carriage bolt, thus making it round. Then I took the file and smoothed out the top of the bolt with the drill running. Next step sanding it then steel wool and last but not least, polishing paste. Looks like chrome bolt now. I basically used the cordless drill as a lathe. ;) |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/03/11 at 05:51:50 Where did I put them... where did I put them... where did I put them... where did I put them...? Rats. I can't find the guts to my switch pods. I know I bagged and marked them, and I thought I put them in the box with all the other bagged and tagged items. I've been going through boxes and drawers, but no luck yet. That's what I get for trying to be orderly. Update: I finally found them -- in a place they shouldn't have been but, in a way, made sense. But where's the kill switch? I remember not liking how faded it was and that I'd paint it. Other than that... I don't know where I put it. |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 07/03/11 at 06:29:50 486A716A477061616D64050 wrote:
Nope, don't need to do that. Either get a smaller size or grind the square under the head into a round. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/03/11 at 06:52:01 Something needs to keep the bolt from spinning. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 07/03/11 at 06:58:06 Counter sink the caps and put flat head bolts on them. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/03/11 at 07:28:12 Again, the problem is finding ones long enough. I think there's some engineering standard that limits head type-bolt length combinations. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 07/03/11 at 08:11:48 Just a tiny bit of JB weld under the head to hold it while you tighten it, OR, Use an impact.. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 07/03/11 at 19:14:56 4B697269447362626E67060 wrote:
How about this? Cut a slot in the end of the carraige bolt so you can hold it still while you tighten the primary nut. Then put an acorn nut over the end of the bolt where the slot is, so you don't have that tacky slot embarrassingly exposed. You'd have to trim the length of the carraige bolt so everything fit nicely, but it would look tidy. http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Motorcycle/Miscellaneous/carraigebolt01b-1.jpg |
|
Title: Re: The Project: Phase 4 Post by arteacher on 07/04/11 at 03:55:05 63415A416C5B4A4A464F2E0 wrote:
You can make a bolt as long as you want with careful welding or threaded collars and threaded rod. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 07/04/11 at 05:47:20 333838313D323329285C0 wrote:
You can make a bolt as long as you want with careful welding or threaded collars and threaded rod.[/quote] Been there, done that,... and it does work. If you enjoy that kind of thing (I do) then you can make any configuration of fastener you want. If you just want a long carraige bolt, find a hex-head bolt the correct length, chuck it in your drill, hold the drill still (vise? foot? buddy?), and use a small grinding wheel in another drill or a dremel and grind the head to the shape of a carraige bolt,.. or any other shape that excites you. (Of course, if you have a lathe available, you can do this the right way.) Then use the slot in the threaded end of the bolt I mentioned above. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/04/11 at 06:24:21 Or a much simpler solution would be to flip the existing bolts so the socket head is at the bottom, then use acorn nuts on top. Acorn nuts always have a nice retro feel. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/04/11 at 07:08:21 If I were going to the trouble of welding (trouble for me because I'd need to have someone else do it), I could peel the rubber cone from the back of the handle bar mount cap, weld the hole shut, then weld it to a bolt and slide the rubber cone back on. I could even epoxy some coins or medallions to the caps. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 07/04/11 at 07:12:53 1D3F243F122534343831500 wrote:
That's too easy! >:( You deny us the chance to fabricate something seven times before we end up with something that works well enough to justify all the time slathered on such a simple part! |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 07/04/11 at 07:20:20 Yea,, that mita been the thread killer right there.. good answer, MB,, |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/04/11 at 08:05:59 Yeah, well sorry to spoil your problem solving and fabbing fun,but... http://i280.photobucket.com/albums/kk182/motobuddha/eda304a0.jpg They still stick up, but at least they look better. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 07/04/11 at 09:21:56 If it were me I would just get a couple of those domed chromed end caps and snap 'em, or glue 'em, in the holes. Or how about a couple more fork tube nuts glued there? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/04/11 at 09:47:31 The bolts are used to mount the gauges. The beast way is to do what RpNSht did -- mill the triple clamp, plug the holes, and tap holes on the bottom side for the gauges. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1304297812/15 (scroll down) |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 07/04/11 at 10:14:01 Not that this is not the prettiest way to go... http://i1226.photobucket.com/albums/ee419/rpnsht/IMG_1466.jpg next would be to have a couple of plugs turned on the lathe to fit the hole and a tapped blind hole on the backside for the gage mounts. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 07/04/11 at 10:35:16 416378634E796868646D0C0 wrote:
Looks nicer. I like the idea of having some frame-matching color, in general. Overall, though, (and this is only my oPINion based on one pic),..... it looks a little too busy with the acorn nuts and the washers and the color. |
|
Title: Re: The Project: Phase 4 Post by Abbey Normal on 07/07/11 at 20:19:46 I'm liking the acorn nuts on top...much cleaner than the hexs. I'm going to have to search out a couple and remount mine. My painter is going through some 'family issues' so my parts are taking a bit longer than anticipated to complete. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/26/11 at 17:15:02 Life has become complicated and I haven't worked on the bike in several weeks. Sigh. Maybe this weekend. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/26/11 at 17:21:11 746770716E6365676C33020 wrote:
Or mill a recess in the top to fit a small digital bicycle speedo, and drill some holes for idiot lights. Don't need a tach. Then find a good metalsmith to properly fill the old speedo hole in the tank... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/30/11 at 08:34:07 Okay, I got back to reassembling the engine this morning. Started out annealing the new copper gasket that was made to fit the 97mm bore job. Once it was all ScotchBrited up, it was a shame it had to be covered up. http://i280.photobucket.com/albums/kk182/motobuddha/fcf78345.jpg An extra set of hands would have made it easier to get the head in place. I had to feed the wire holding the cam chain up into the slot, then hold it in my mouth while fiddling the chain guide into place and lining the head up over the studs. http://i280.photobucket.com/albums/kk182/motobuddha/d84caa67.jpg The four main bolts are torqued to spec, but I need to get a 12mm open end wrench attachment for the torque wrench in order to do the acorn nuts at the front and back. Then it's on to installing the new cam. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/30/11 at 12:42:29 http://i280.photobucket.com/albums/kk182/motobuddha/d0123b5f.jpg Okay, the top end is back together. Woo! Here's the new cam in place. There's a certain zen required to get the cam, sprocket and chain into position -- with the witness marks in the right place. I lack the necessary amount of that zen. http://i280.photobucket.com/albums/kk182/motobuddha/0ed8c5ca.jpg I replaced the long bolt on the front left corner of the head rather than just cutting it off or discarding it. The new one is stainless steel with SS washers and a chrome acorn nut. I have some extra sets if anyone is interested. http://i280.photobucket.com/albums/kk182/motobuddha/4e7d62de.jpg http://i280.photobucket.com/albums/kk182/motobuddha/ca020996.jpg I also installed a verslavey with my new chain. Shouldn't need to worry about that problem for a while. http://i280.photobucket.com/albums/kk182/motobuddha/2e554c8a.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/30/11 at 14:16:33 Feelin' arty. http://i280.photobucket.com/albums/kk182/motobuddha/4f5f79e1.jpg |
|
Title: Re: The Project: Phase 4 Post by mmosel on 07/30/11 at 15:35:05 Thanks for sharing your pics, very awesome. If I ever get a spare bike, I will take it all apart just for the experience of it. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 07/30/11 at 16:04:12 I have been following this thread for a long time now and I must say what a beautiful machine it will be when finished. If some magazines don't do an article on it it's their loss. Personally I would be reluctant to ride it, or even let it get dirty. |
|
Title: Re: The Project: Phase 4 Post by Serowbot on 07/30/11 at 18:38:54 This has got to be the most perfectly built Savage in history... I would eat off any part of it... Question?.... How many phases are there?.... :-?... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 07/30/11 at 18:52:31 796F78657D68657E0A0 wrote:
Man, I hope just four. |
|
Title: Re: The Project: Phase 4 Post by Serowbot on 07/30/11 at 18:54:23 ;D ;D ;D... I can't wait!... |
|
Title: Re: The Project: Phase 4 Post by Digger on 08/12/11 at 19:20:26 Moto, I have a question from a post you made in the "Phase 2" thread (I'm asking it here since I didn't want to mess up your "Phase order." :) 75574C577A4D5C5C5059380 wrote:
Do you recall if that wheel balanced out well before you mounted the tire? TIA! |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 08/12/11 at 20:12:04 Did you use the line up on the tire? Theres a mark, sposed to line up with the valve stem.. |
|
Title: Re: The Project: Phase 4 Post by mmosel on 08/12/11 at 20:27:00 I can't wait to see this bike come together. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 08/13/11 at 06:19:19 4E636D6D6F780A0 wrote:
Do you recall if that wheel balanced out well before you mounted the tire? TIA![/quote] No, I didn't think to check the wheel without the tire. I suppose the rim could be off center from the axle. I can check that. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 08/13/11 at 06:19:53 5E55555C505F5E4445310 wrote:
On second thought you should have built two. One without all the sanding and polishing to run around on and the one you are doing to sit in a lawn chair with your favorite beverage and look at. ;D |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 08/13/11 at 06:20:14 3F2026213C3B0A3A0A32202C67550 wrote:
Yes. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 09/14/11 at 17:40:10 So, real life has been keeping me from making progress on this. Also, I've been trying to find some missing bits. I've been going a little nuts trying to find the guts of the switch pods. I'd looked everywhere. Several times. I was about to order some second-hand replacements but made one more pass through the garage. Finally, as I looked in the drawer that contained the wiring harness, it struck me. Oh, maybe they're in here. Yes, they were. I had forgotten the small parts were attached to long wire bundles. I had been looking for a couple of baggies. Head smack, head smack, head smack. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 09/14/11 at 17:49:36 So, I had applied the RVT and bolted on the head cover slightly more than finger tight. Later, I got out the torque wrench to properly tighten it. I checked the specs in the manual, set the wrench and went to work. No problem -- until I got to the dreaded left front bolt. On all the others, the wrench clicked after about 1/8 to 1/4 turn, but the left front kept turning past 1/4, on past 1/2. Had it just been looser, or were the threads stripping, as is common? I decided to stop and cross my fingers. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/10/11 at 15:30:15 I finally got my head out of other things long enough to get the engine placed back in the frame. It's not all bolted in, because I need to get the tape off and fiddle with some other things, but at least it's off the stand. I hung the pipe temporarily just so I'd think I was farther along than I am. http://i280.photobucket.com/albums/kk182/motobuddha/17e2f174.jpg |
|
Title: Re: The Project: Phase 4 Post by Serowbot on 10/10/11 at 15:51:33 Will you hurry up?... The hairs on my arms are standing up,.. and I don't think they'll go back down, 'till I see it done... ;D... |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 10/11/11 at 04:19:29 wow, an update has been sooooo long coming that I almost forgot about this build :'( |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/11/11 at 06:43:54 Yeah, it makes me sad too that I haven't been able to make more progress. Life has been wanting other things from me. |
|
Title: Re: The Project: Phase 4 Post by LANCER on 10/11/11 at 10:53:27 Stuff happens you do what you can when you can |
|
Title: Re: The Project: Phase 4 Post by dasch on 10/11/11 at 12:03:09 Buddha, this is a masterpiece as it is!!! Man, looks so good, I'd hang it in my living room! Congrats! :) :) :) :) |
|
Title: Re: The Project: Phase 4 Post by splash07 on 10/11/11 at 12:06:02 795B405B764150505C55340 wrote:
Life is funny that way |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/11/11 at 12:06:27 Spent some time with my painter buddy. Rather than attach the ignition/idiot lights plate to the tank the standard Ryca way, we cut the three tabs off the speedo cavity and welded the plate in position. (We kept the bolts on the plate for mounting the ignition and lights.) Then he'll bondo the seam and give it a nice taper. |
|
Title: Re: The Project: Phase 4 Post by crackmonkey on 10/11/11 at 18:32:47 that will be sweet man. it is really coming together nice |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/13/11 at 13:49:44 Pulled off the tape and bolted up the engine mounts. I also test fitted the exhaust and carb. http://i280.photobucket.com/albums/kk182/motobuddha/24426ef5.jpg Since one of the engine/footpeg bracket bolts on the left side needs to be a button head in order for the chain to clear, I swapped out SS button head bolts in all four positions. Any excuse to use stainless steel. http://i280.photobucket.com/albums/kk182/motobuddha/d3b019ed.jpg The spots where the battery box used to mout are just begging for something else. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/13/11 at 16:03:45 I decided to bite the bullet and get one of those light, compact lithium batteries. 210 CCA. About four pounds lighter. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/14/11 at 09:10:23 Had to grind down the frame stubs a bit so the seat platform would fit. I had cut them a little long just to be safe. Hurray for the angle grinder. http://i280.photobucket.com/albums/kk182/motobuddha/dc3d16f9.jpg Guess I should get the engine covers on. |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 10/14/11 at 09:48:10 4F6D766D407766666A63020 wrote:
will the ignition plate be flush with the rest of the tank or will it be raised, positioned on top of the lip? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/14/11 at 09:57:25 59464B4B424D464F475C5D5A5B405A402E0 wrote:
will the ignition plate be flush with the rest of the tank or will it be raised, positioned on top of the lip?[/quote] It will still be raised. We didn't want to deal with any issues that might develop if we cut down the lip on the tank. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/15/11 at 12:29:29 Buttoned up the clutch side after making a run to the store for a cotter pin. Had to fiddle with some other things. For example, back when I started the project I had cut off the frame protrusions where the forward controls used to mount way before Ryca sent out it's instructions for that, so I had cut mine almost flush with the frame. That meant the engine mounting bolts Ryca supplied were about a half inch too long on one and an inch too long on the other. So I cut the bolts down. I also cut the required inch off the exhaust pipe and mounted the crumb cup in the muffler. I made the hole in the muffler mounting strap larger so it would fit over the 10mm bolt. I test fitted the chain to confirm it still okay since the frame had been coated and actually assembled. I fiddled with the wiring some more. Except for the clutch cover, there's not much that looks different from the previous shot. http://i280.photobucket.com/albums/kk182/motobuddha/13c5ba8e.jpg |
|
Title: Re: The Project: Phase 4 Post by PerrydaSavage on 10/16/11 at 02:33:55 Wicked, wicked, wicked!! What a Build!! Can't wait to see it finished!! Congrats man! 8-) |
|
Title: Re: The Project: Phase 4 Post by LANCER on 10/16/11 at 07:40:22 B E A UTIFUL :) |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/16/11 at 10:46:53 Like others, I was having trouble getting the air filter to fit. Then I watched the Ryca video on the matter and understood what I needed to do. I got it on, but the filter was tilted downward a bit. After rechecking things I saw part of the frame crossmember was bent. So I straightened it and everything fit fine. http://i280.photobucket.com/albums/kk182/motobuddha/d25d1d5f.jpg However, I don't know that I like the top of the filter touching the crossmember. Vibrations can make it do unwanted things. So I'm going to try bending the crossmember upward some more to see if I can get a little clearance. |
|
Title: Re: The Project: Phase 4 Post by crackmonkey on 10/16/11 at 12:03:44 yeah i dont think i would like that touching either. i know you already have it painted the frame but maybe cutting that piece out would be an option if you cant get good clearance from bending. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/16/11 at 13:46:04 Spent the afternoon dealing with the rat's nest of wiring. Or, rather, it was dealing with me. I need to figure out how to route things with the relocated parts. I thought I had most of it figured out until I realized I needed to get the carb, cables, etc. in place. I want to keep as much of the wiring as possible out of sight. I've been trying to be all zen about it, letting the bends and twists of the wires tell me where they want to go. Eh. http://i280.photobucket.com/albums/kk182/motobuddha/caabcfaa.jpg |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/17/11 at 09:42:31 12302B301D2A3B3B373E5F0 wrote:
I'm at this point as well. PLEASE,.... save me a lot of work here (I have two bikes to do, eh?) I have the same desires,.. I want the wiring to be the least untidy. Once you get a clean routing worked out, please post lots of pics. Gracias Muchissima. Ken Slabaugh did an outstanding job on his CS-1,.. the wiring looks airworthy even. He emailed some pics to me. I can send them to you, or when I get some time post them here. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/17/11 at 09:48:08 7D4348555855583A0 wrote:
I'm at this point as well. PLEASE,.... save me a lot of work here (I have two bikes to do, eh?) I have the same desires,.. I want the wiring to be the least untidy. Once you get a clean routing worked out, please post lots of pics. Gracias Muchissima. Ken Slabaugh did an outstanding job on his CS-1,.. the wiring looks airworthy even. He emailed some pics to me. I can send them to you, or when I get some time post them here.[/quote] I spent some time this morning (one of the "benefits" of being underemployed) cutting back the factory electrical tape so things would route better. Now I'm about to lengthen the ignition switch wires, after I make a run to the store for some wire. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/17/11 at 12:40:22 There is a way to lengthen the ignition switch wiring at http://suzukisavage.com/cgi-bin/YaBB.pl?num=1312137269. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/17/11 at 13:03:19 Yeah, I had seen that and did pretty much the same thing, soldering the connections and all that. I panicked for a moment because I had two brown wires and hadn't marked which was which. But then I noticed they both went to the same point on the connector, so it didn't matter. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 10/17/11 at 13:07:42 Yea, I thot I made a mistake once, too,, but I was wrong.. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/17/11 at 13:40:19 75574C577A4D5C5C5059380 wrote:
On both our bikes, even peening that cross piece above level didn't make enough room. The carb is still not true in the mount on the cylinder. Also, there is a clearance problem with the tank hold-down screwheads and the air filter. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 10/17/11 at 13:52:27 Maybe getting a wedge shaped spacer made to tilt the carb down a bit is a decent answer? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/17/11 at 15:05:22 Since my bike originally had buckhorn bars, I need to have shorter cables made up. It took me a while to figure out how much to shorten each cable, what with the fittings, elbows and such. But then it hit me. -- Attach one end of a cable in place, route it where it needs to go, with the bars turned all the way to the position that would require the most length -- bars turned to the left for the clutch and speedo, to the right for the throttle. -- Choose a reference point on the chassis, like a bolt, and mark the cable. -- Unattach the end you had attached and attach the other end, routing the cable the same way. Mark the cable again, using the same reference point. The distance between the two marks is how much shorter the new cable needs to be. Now that I have that figured out, I'll be sending the two old cables and the way-too-long new Ryca speedo cable off to Motion Pro to have new ones made. http://www.motionpro.com/motorcycle/custom/ |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/18/11 at 12:53:13 I'm not the most organized guy. I had put parts for this bike in several places -- places that made perfect sense at the time. That means I've spent a lot of time lately searching all those places for odd parts. The latest quest was the cable that activates the rear switch for the brake light. I finally found it in a drawer I'd looked in three or four times before -- a large drawer that had only four items in it. It was like I had a malfunctioning part of my brain that saw the cable but didn't recognize it. Man, getting old sucks. Then I tried to remember how the cable mounted. I knew the end near the switch had to attach to something. Had I cut that tab off when I was in a tab cutting frenzy? That wouldn't be good. I finally located it with my fingers. Ah, good. But the cable was a filthy mess, like so many of the things on this bike were. And the cable didn't move smoothly in the sleeve. So now it's soaking in Berryman's. Once that's done, the trick will be to see if I can route it a better way than the standard Ryca way. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/18/11 at 14:39:43 Ooooo, look what the brown truck brought! Welcome to the 21st Century. http://i280.photobucket.com/albums/kk182/motobuddha/bb1f0d6c.jpg |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 10/18/11 at 15:25:57 " It was like I had a malfunctioning part of my brain that saw the cable but didn't recognize it." My wife calls this MALE REFRIGERATOR BLINDNESS. According to her it applies all over the house... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/19/11 at 17:48:33 I got some of these to have a little fun with. If nothing else it's fun to say Dzus. http://i280.photobucket.com/albums/kk182/motobuddha/d89a0dad.jpg |
|
Title: Re: The Project: Phase 4 Post by Serowbot on 10/19/11 at 18:38:54 13312A311C2B3A3A363F5E0 wrote:
What Dzus they do?... :-?... Where Dzus they go?... :-?... Why Dzus you need them.. :-?... I think I Dzus want some too... :-?... Dzus they cost a lot?... :-?... |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/19/11 at 19:51:15 I knew a guy who pronounced the name of these fasteners as if it rhymed with "Jesus." He also had a Bye - ant - chee shotgun. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/19/11 at 20:41:55 6E786F726A7F72691D0 wrote:
What Dzus they do?... :-?... Where Dzus they go?... :-?... Why Dzus you need them.. :-?... I think I Dzus want some too... :-?... Dzus they cost a lot?... :-?...[/quote] I'm going to do something I hope will be unique, so I'm not going to tell you. Neener neener neener. I got a 10-pack of them, including the back springs, for about $15.00 from Summit Racing. |
|
Title: Re: The Project: Phase 4 Post by Serowbot on 10/19/11 at 22:18:53 Arrrrghhhh!.... @*@?@%#$$&!!!!!... Hurry up and get that thing together!... >:(... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/20/11 at 04:59:13 241A110C010C01630 wrote:
What Would Dzus Do? |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/20/11 at 08:10:04 7C5E455E734455555950310 wrote:
What Would Dzus Do?[/quote] He would clamp down hard and hold everything together. His one problem, though, is money. He could be undone by a dime. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/20/11 at 09:31:58 As you can see, I started cutting up the battery box and frame (wish I had something other than an angle grinder) in order to get the air filter to sit properly. I thought I had it close enough to the correct position the other day after bending up part of the cross piece, but the carb wasn't completely seated in the intake boot. http://i280.photobucket.com/albums/kk182/motobuddha/74ea4d67.jpg So first I cut off the part of the crosspiece I'd bent up. That didn't help. It was hitting the battery box. So I cut back part of the box. That's when I saw the filter might be hitting the bolts. Some button head bolts would gain me a wee bit more, but not enough. (There are short screws in the photo, because I got tired of removing and replacing the long ones.) http://i280.photobucket.com/albums/kk182/motobuddha/6f4933ca.jpg The filter was still angled like this. http://i280.photobucket.com/albums/kk182/motobuddha/9b3472cc.jpg So I've decided to scrap the filter and try this cone shaped one. http://www.knfilters.com/search/product.aspx?Prod=RC-1250 I was hoping K&N had a suitable size with an angled flange, but no. Again, since I'm using a compact lithium battery, I'll have room for the end of the filter. If I need to, I'll move the rectifier elsewhere, like the inside back of the battery box. |
|
Title: Re: The Project: Phase 4 Post by LANCER on 10/20/11 at 10:46:12 77554E55784F5E5E525B3A0 wrote:
Aren't they perty ? Oh yea. They have been used on aircraft for lots of years They make installing and removing sheet metal or small parts EASY and when locked they are extremely secure. I love em. I had a source for them in wholesale quanties a year or two ago but not sure now. Does RYCA use them ? I don't remember right off hand. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/20/11 at 10:51:04 6D606F6264733336010 wrote:
No. And I'm going to use them just for looks, not function. This time. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/20/11 at 11:10:35 4C6E756E437465656960010 wrote:
No. And I'm going to use them just for looks, not function. This time.[/quote] There could be some cool ways to use them for the side panels and maybe the seat. |
|
Title: Re: The Project: Phase 4 Post by spacepirates on 10/20/11 at 11:25:50 Before you go spending another $50 on filters, you might see if you can rig up something else for cheap first, like an angled air intake system. I think there are some pvc fittings that measure pretty close to the carb inlet diameter. Maybe if you got a rubber coupler for a few bucks you could slice and dice and make something work? I can't really see what kind of space you have from these pics (and i'm too lazy to look through the thread to find them). You could try a 90 degree elbow and point the filter down (or out the side, i guess). |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/20/11 at 13:27:29 5C5F4E4C4A5F465D4E5B4A5C2F0 wrote:
There's just not enough room between the cyl head and the RYCA battery box for any angle adaptors etc. I'm working the same problem myself times 2. I think I have a solution. I'll post pics in a day or two. |
|
Title: Re: The Project: Phase 4 Post by wombat on 10/20/11 at 15:33:19 Forget buying another K&N. I've used a small clamp-on chrome pod filter from UNI. Fits with "almost" no cutting. 614358436E594848444D2C0 wrote:
|
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/20/11 at 17:57:27 A UNI is looking like a good solution. Thanks for the tip. I can only find them in a 2-pack. Does someone want the extra one? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/21/11 at 09:13:31 Paid a visit to the painter. The bodywork is in progress. http://i280.photobucket.com/albums/kk182/motobuddha/99bc6937.jpg http://i280.photobucket.com/albums/kk182/motobuddha/cffd6ddd.jpg The tank originally had some dings where the windscreen mounting brackets hit it. The stock cap was also in bad shape, so I decided to replace it with the old standard twist-on style. The old neck was cut off and a new one welded on. We used some Caswell epoxy-based sealer on the inside to deal with any rust. The stuff dries clear and shiny, like bar top varnish. You can see that we welded the ignition/lights plate to the tank and now he's smoothing in the seam. By the way, here's his website: http://www.bdscycles.com/examples.htm |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 10/21/11 at 13:38:03 795B405B764150505C55340 wrote:
i was going to have the ignition plate welded to the tank as well but decided not to after realizing how big of ordeal it would have been to get it completely flush with the rest of the tank. your tank is going to look awesome and cant wait to see it finished |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/22/11 at 18:02:54 Remember when I said I was going to work on the air filter fitment issue? Well,... they don't call me "Follow Through Bob" for nuttin' See reply #121 in Double RYCA build for the full story. http://www.bluemelon.com/photo/42589/1832599-T800600.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/22/11 at 19:47:45 Yeah, I saw your thread. I fiddled with some things today. I think I might end up moving the rectifier to the exterior right side of the battery box, cut away most of the front and let the Uni filter stick through. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 10/22/11 at 22:14:23 Nice lookin job, good welds,, lots quicker & easier than a wedge shaped spacer. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/26/11 at 11:24:24 I got a PK-92 UNI filter and it solves all my problems. The carb is properly attached to the engine and the filter clears everything. The diameter is less than the K&N that Ryca supplies, but it's also longer, so it allows at least as much airflow, if not more. And since it's flexible (foam over a coil spring) it's easier to deal with. http://i280.photobucket.com/albums/kk182/motobuddha/bdc98c24.jpg As you can see below, there's no contact with heads of the battery box/tank/seat mounting bolts. It also clears the rectifier and the main part of the battery box. http://i280.photobucket.com/albums/kk182/motobuddha/9b95083b.jpg http://i280.photobucket.com/albums/kk182/motobuddha/dce6cd9b.jpg It might have been unnecessary to cut the frame crossmember, and I obviously didn't need to cut away as much of the battery box. I'll go with this for now. Someday, when I'm feeling flush, I buy another battery box and have someone with more tools than me make the perfect clearance cuts. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/26/11 at 17:38:38 What are you going to do about a crankcase breather? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/26/11 at 18:01:02 It would probably be easy to cut a hole in the side of the UNI filter and then seal the end of the hose with silicone. But I'm also looking for a small catch can. And there are filtered plugs the size of the tube. I might do that. Oh, I have a second UNI filter because they only come in 2-packs. Does anyone want it? |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/27/11 at 06:53:00 How many cuts do you have to make to get it to fit? If not many, I'll take it :D |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/27/11 at 07:38:25 I think one could get away with leaving the frame crossmember alone and cutting only the front top of the battery box as shown by the dotted line. Some other cuts would probably need to be made to compensate for losing some of the wiring hole. http://i280.photobucket.com/albums/kk182/motobuddha/bb59ce3e.jpg |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/27/11 at 12:16:24 I'm gonna pass, I'm not setup to relocate my Big Crank battery at the moment. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/27/11 at 14:16:46 I think you could still fit your battery if you cut the box like this. http://i280.photobucket.com/albums/kk182/motobuddha/217e11fd.jpg The cuts do nothing to the actual battery compartment, just the part that connects to the tank/seat mount. |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/27/11 at 14:24:07 Lemme go have a look at the side panels and take off the seat and see what I'm workin with.. she's settin apart in the basement waiting for parts already :D |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/28/11 at 12:15:17 I'm swearing at the wiring harness. Maybe one of you other Ryca builders can help me out here. After the big relay that attaches at the Y of the frame, the harness branches out with the connector for the CDI on one side (left) and the fuse holder on the other (right). After the fuse holder are the wires for lights, signals, ignition and such. With me so far? I had the harness zip tied to the right (starboard) side of the frame, with the branch for the CDI crossing over to the left side between the air filter and battery box. That seemed to work okay until I tried to connect one of the small wires coming up from the left side of the engine. It wouldn't reach. Rats. I suppose I could lengthen that wire, but before doing that, I want to know if there's a better way to route the harness. Pictures would be appreciated. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/29/11 at 09:24:26 I figured it out. I had made two main mistakes. The first was at the front of the bike where I had the whole harness anchored too far forward. The second was that I had run the harness down the right side of the bike instead of the left. I swapped it over and, presto, everything started to fit. Now I just need to decide how I'm going to mount the CDI box. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/29/11 at 10:22:47 Shorty muffler? Thinkin' about it... thinkin' about it... looks versus performance... looks versus performance... thinkin' about it... http://i280.photobucket.com/albums/kk182/motobuddha/bf86ba87.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/29/11 at 13:13:24 I didn't want extra wires and cables flopping around, so besides having shorter cables made, I'm shortening the wires from the control pods. After some fiddling and figuring, I cut about 6 inches out of the right bundle and then practiced my soldering skills. http://i280.photobucket.com/albums/kk182/motobuddha/fc6e5da4.jpg All put back together, it should tuck in quite nicely. http://i280.photobucket.com/albums/kk182/motobuddha/43161af8.jpg (The ignition switch is just temporarily zip tied while I get the wiring figured out.) |
|
Title: Re: The Project: Phase 4 Post by jandaso on 10/29/11 at 17:19:05 You seem to has gone both ways: looks and performance. Im going with a drag pipe but running from the top of the engine cover. 8-) |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/29/11 at 18:16:22 Performance.. then make it look good :) |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 10/30/11 at 06:46:28 where did u get that shorty muffler and what brand is it? Need something like that for my '75 honda cb200T cafe build. |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 10/30/11 at 06:46:39 where did u get that shorty muffler and what brand is it? Need something like that for my '75 honda cb200T cafe build. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/30/11 at 08:27:30 It's an Emgo product, available from MANY sources. One end is 1.75" and the other is 1.5". Either end can attach to a pipe. I found it googling "shorty muffler, motorcycle" and clicked the images function to see if it was the type I was looking for. I got it from PowersportSuperstore.com |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 10/30/11 at 11:08:14 05273C270A3D2C2C2029480 wrote:
That thing is going to put new meaning in the term BLAT!!! I'll bet it sounds cool cruising along, part throttle, at 45 or 50, though. |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/30/11 at 13:15:36 MotoBuddha, do you have that muffler angled out any? You're gonna blacken anything behind it.. like rear drum brake arm, possibly your frame too... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/30/11 at 13:29:10 It can angle out a little, but right now it's just in place while I decide whether I want to go with it or not. |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/30/11 at 15:16:29 5E7C677C516677777B72130 wrote:
I hope you decide to... |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 10/30/11 at 18:43:13 buddha, can you do me one favor? What is the diameter of that shorty pipe at the widest point? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 10/31/11 at 05:29:55 It's about 2.5" |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 10/31/11 at 07:06:44 Take this and divide the sound? [media]http://www.youtube.com/watch?v=N0JZ7Dw9K6E[/media] |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/01/11 at 06:00:01 I just talked to the painter. Everything is done except for the pin striping -- and the pin striper hasn't been returning calls. So now I need to call him to see if he's pissed at the painter, just being flakey, or something else. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 11/01/11 at 07:45:11 Maybe he runned outta tape? |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/01/11 at 12:30:26 Stripes make it go faster, that's why he's pissed.. I would be too... But if I was puttin flames on it.. you'd never see it again... :D |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/02/11 at 15:27:10 Stopped by the painter again. Making progress. Now if only the pin striper would return calls. http://i280.photobucket.com/albums/kk182/motobuddha/c2766988.jpg http://i280.photobucket.com/albums/kk182/motobuddha/e3309c77.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/02/11 at 15:42:49 When the painter did the headlight bucket, he also filled the dimple. http://i280.photobucket.com/albums/kk182/motobuddha/bf15e259.jpg |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 11/02/11 at 18:24:57 it's called a sprue that's where the plastic is injected. I don't know why they did it on the outside wouldn't been visible on the inside. |
|
Title: Re: The Project: Phase 4 Post by jandaso on 11/02/11 at 19:19:09 Your bike is going to look sweeeeetttttt... 8-) |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 11/03/11 at 06:34:08 Same thing here on my buddy's bike. This is his bucket sitting on one of my side panels.(Double RYCA Build) http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Motorcycle/RYCA%20CS-1%20LS650%20S40%20Savage/RYCAcolorcompare1a.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/03/11 at 08:08:34 The silly thing, though, is that you can't see the dimple/sprue once the headlight is mounted. But I'd know it was there if it hadn't been filled. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/03/11 at 09:38:17 Am I correct in thinking the light that illuminates the stock speedometer is always on? |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 11/03/11 at 09:46:45 No it goes off when you turn the key off. ;D |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/03/11 at 10:43:27 Thanks, smartypants. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/04/11 at 10:53:28 The pin striper finally arrived from 1979 to do his thing. I can't wait to see everything with the clear coat, all buffed up. http://i280.photobucket.com/albums/kk182/motobuddha/4816dc72.jpg http://i280.photobucket.com/albums/kk182/motobuddha/bf34f62f.jpg http://i280.photobucket.com/albums/kk182/motobuddha/962659c8.jpg http://i280.photobucket.com/albums/kk182/motobuddha/4a6bcd46.jpg |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/04/11 at 16:57:23 is that not one, but two packs of smokes in his front pocket? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/04/11 at 17:22:36 They're for balance. ;D |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 11/05/11 at 07:08:59 THAT GUY looks like the real deal! I sure hope his work is as good as his look... Can't wait to see it! |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 11/05/11 at 07:20:08 Ill bet that heater & the AC do great out there in that Zero Insulation building. If I get 3 feet from the wood stove in my shop, I cant even tell its lit. I just fire up the heater & get in front of it when IM too cold to do anything. When the feet get too cold, its time to warm up. I wonder if that guy ever smoked any pot. |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/05/11 at 11:16:05 That makes me nervous seeing someone paint a stripe by hand with zero room for error :-X |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 11/05/11 at 12:49:02 6D7A66637B3D636E7C7B39390F0 wrote:
As long as he smoked enough pot, it should be flawless! |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/05/11 at 13:10:11 584F53564E08565B494E0C0C3A0 wrote:
Actually, if he messed up, he has the right solvent to wipe it off without bothering the base paint. |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 11/05/11 at 13:33:07 I knew a guy once who had some pin stripin' done. Said this old drunk walked up with trembling hands with a brush in his hand... my buddy starts to sweat, says hey is he alright? owner of the shop just says wait you'll see. As soon as mr dt touches brush to paint the tremblin stops and he lays down a perfectly straight line. Best job he's ever seen. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/05/11 at 13:54:44 Spent some time shortening the left side control wires. I had to cut back the sleeve quite a bit and unbundle things, what with branches for the turn signals, horn and some mystery connector. I think the wires must have spent a previous life as Christmas lights. Either that or the folks working the wiring harness production line like to break the boredom by randomly tangling the wires. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/05/11 at 15:07:45 I think I figured out how to handle the crankcase breather. I found a corrosion-resistant industrial breather. http://i280.photobucket.com/albums/kk182/motobuddha/30c99429.jpg The inside diameter is a perfect match for the outside diameter of the stock breather tube. I epoxied the breather to the tube and then tidied it up with some heat shrink. http://i280.photobucket.com/albums/kk182/motobuddha/b33eba4f.jpg I positioned it so that whatever happens to blow past the breather filter has a good chance of being sucked toward the air filter, which will be oiled anyway. |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/06/11 at 04:33:30 2E0C170C211607070B02630 wrote:
SLICK! |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/06/11 at 05:20:55 1E3C273C112637373B32530 wrote:
Actually, if he messed up, he has the right solvent to wipe it off without bothering the base paint.[/quote] I had a feeling he had something to remove any blemishes.. but still, micro work like still makes the hair on my neck stand, because it has to be perfect :D |
|
Title: Re: The Project: Phase 4 Post by arteacher on 11/06/11 at 05:49:37 My grandfather was a commercial artist for Jones Box and Label here in London. Among his designs were the Schneider's Meats girl with the pigtails (still in use), Labatts Brewing, and old Campbell soup labels. I never saw it but my dad said he would do all the lettering for the labels freehand at twice actual size, and it was amazing to watch him work. And he didn't smoke dope. ;D |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 11/07/11 at 11:43:48 42607B604D7A6B6B676E0F0 wrote:
where did you find this at? any leads would be rad thanks! |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/07/11 at 13:14:10 Aw, come on, man. I do all the scrounging and stuff so I can have something different. It would defeat the purpose to make it easy for people to copy me. ;) |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/07/11 at 21:44:02 416378634E796868646D0C0 wrote:
LOL you're rockin, keep it goin... |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 11/08/11 at 10:45:02 705249527F485959555C3D0 wrote:
easy there- i thought this forum was about sharing... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/08/11 at 11:17:16 I thought it was about sharing how clever I am. ;D |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/08/11 at 11:30:22 Motobuddha hows that air filter working out for ya? Is it pretty high performance? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/08/11 at 13:07:55 Things aren't ready to run yet, so I don't know. But they've been used a long time on dirt bikes, carts, snowmobiles and other things. |
|
Title: Re: The Project: Phase 4 Post by Finney138 on 11/08/11 at 13:52:05 im runnin the uni without the red outside foam too, i have no complaints, made it sound a bit more throaty, possibly a bit hesitant but i only have the stock box to compare too |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/09/11 at 13:21:10 The shortened throttle and clutch cables arrived today from MotionPro. Since the speedometer cable supplied by Ryca was way too long for my tastes, I had MotionPro make up a new one -- longer than stock, shorter than Ryca. I had them leave off the decorative spring. http://i280.photobucket.com/albums/kk182/motobuddha/ab4c1a6f.jpg I'm going to pick up the bodywork tomorrow. Guess what I'll be doing this weekend. Or sooner. |
|
Title: Re: The Project: Phase 4 Post by crackmonkey on 11/09/11 at 14:07:55 sick so you are leaving the shorty muffler for now? |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/09/11 at 14:52:17 Motobuddha that looks sweet, I hope that exhaust is angled out at least 10 degrees.. else you're gonna have some black parts back there... anyways, better throw that titanium wrap I sent on their somewhere.. gonna add a cosmetic badboy edge to it.. which is just over kill already.. nothing wrong with overkill on the badboy edge though :D |
|
Title: Re: The Project: Phase 4 Post by built2last66 on 11/09/11 at 14:53:37 342536343C3A38393C322E570 wrote:
I can't wait to hear that sick $20 muffler with a cone air filter... ;) |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/09/11 at 15:22:26 66716D687036686577703232040 wrote:
I can't wait to hear that sick $20 muffler with a cone air filter... ;)[/quote] There are some local Harley hangouts I want terrorize a bit. ;D After that I'll probably go back to the reverse cone. |
|
Title: Re: The Project: Phase 4 Post by splash07 on 11/10/11 at 05:54:06 Bike is Lookin Good |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/10/11 at 11:04:41 Well rats. The paint isn't going to be done until Monday or Tuesday. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/13/11 at 10:15:32 If I think about something long enough, the solution comes to me. Case in point: I got bar-end turn signals from Oberon, specifying the version for 1" bars. But when I tried to install them, the collets (the part that expands inside the handlebar) wouldn't go in. Head smack. The collets were designed for steel bars, which have thinner walls than aluminum bars. My first thought was to bore out about an inch of the end of the bars with my stepped bit. That didn't work for various reasons. I emailed Oberon to find out about getting just the collets for 7/8" bars. They never answered. Okay, I could make the brass collets smaller. But how? I could get a friend of a friend to turn them down on his lathe. But that would mean calling in favors I didn't have and waiting for him to get around to it. Or I could shop around for a machine shop willing to do it at a price I'd be willing to pay. Mmmmm, maybe as a last resort. Then a possible solution came to me as I was going to sleep last night. Ah-ha! So this morning I disassembled the collets and chucked them up in my drill. Then I held the spinning collets to my spinning angle grinder. A few seconds of grinding on each and, presto, perfect fit! http://i280.photobucket.com/albums/kk182/motobuddha/5aa2b011.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/14/11 at 15:47:18 I fiddled around with the rear brake switch cable. I got it so it's less obtrusive. It'll do until I figure out an alternative that doesn't require a cable. http://i280.photobucket.com/albums/kk182/motobuddha/759142bb.jpg Now I need to figure out what to do with the unneeded passenger footpeg mount on the swingarm. I'm thinking of some kind of medallion. |
|
Title: Re: The Project: Phase 4 Post by splash07 on 11/15/11 at 11:58:57 A bottle opener would go great there. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/15/11 at 13:01:51 37342825372C7473440 wrote:
Or maybe cover it with a bottle cap. |
|
Title: Re: The Project: Phase 4 Post by Smokestack on 11/15/11 at 13:54:38 45677C674A7D6C6C6069080 wrote:
See, that right there is a great idea. |
|
Title: Re: The Project: Phase 4 Post by MrBrownTX on 11/15/11 at 14:37:19 02203B200D3A2B2B272E4F0 wrote:
Or maybe cover it with a bottle cap.[/quote] a Shiner bottle cap! http://t3.gstatic.com/images?q=tbn:ANd9GcT_sLRbuEj6HV6qnCM5n0nld8GD_8hBiQZrKlm2d0ZXS946VD-grw:i.colnect.net/images/f/336/638/Shiner.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/16/11 at 21:03:55 Had another senior brain fart moment. I had the wiring harness all worked out, except..... Where the hell is the connection for the headlight? I had myself convinced I was missing a length of wiring and a couple of connectors. I was cussing and fuming. But then I poked around on the bike and, doh, found where I'd tucked the necessary connector temporarily out of the way. Head smack. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/18/11 at 08:53:51 Sigh. Perfection takes time. The painter discovered some tiny pits along the edges of the fiberglass body parts. This was after applying clear coat. He had to sand down the edges, apply filler, base coat and new clear. So now I'll get the parts Monday at the earliest. |
|
Title: Re: The Project: Phase 4 Post by crackmonkey on 11/20/11 at 10:53:33 that is awesome. not many people take that much pride in their work anymore. at least you know it is being done right |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/22/11 at 06:01:47 The painter just sent me this picture. http://i280.photobucket.com/albums/kk182/motobuddha/5413c869.jpg |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 11/22/11 at 06:02:55 Thats gonna be one purtee thang.. |
|
Title: Re: The Project: Phase 4 Post by LANCER on 11/22/11 at 07:42:17 Wow, nice paint job ! That will look really good on the bike. :) |
|
Title: Re: The Project: Phase 4 Post by splash07 on 11/22/11 at 11:53:54 shes gunna be purty |
|
Title: Re: The Project: Phase 4 Post by T2 on 11/22/11 at 14:46:59 Is there a reason you have a "6" on one side and a "9" on the other? Is that some kinda secret RYCA code? On the other hand...WOW! |
|
Title: Re: The Project: Phase 4 Post by bill67 on 11/22/11 at 16:12:53 Thats 2 9's 1 more 9 and he can run for president. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/22/11 at 16:23:58 73787D7D2726110 wrote:
Or live in Sim City. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/23/11 at 11:42:45 Picked up the bodywork! The seat and side covers are just resting in place in this photo, but it looks a lot more done than it did. http://i280.photobucket.com/albums/kk182/motobuddha/e2373254.jpg Saturday will be the 1-year anniversary of rescuing the bike. The original plan was for it to be ready to ride by March. I guess I forgot to specify March 2011. http://i280.photobucket.com/albums/kk182/motobuddha/5d98dba4.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/23/11 at 14:04:48 Here's a closeup of the welded on and molded in ignition/lights panel (with the lights not installed yet). http://i280.photobucket.com/albums/kk182/motobuddha/646fa123.jpg |
|
Title: Re: The Project: Phase 4 Post by jandaso on 11/23/11 at 14:37:46 That looks really Good man. Congrats. That paint looks so good. I was thinking of putting those clear film to protect (have it on my car) some of the parts on the tank because Im always wearing a belt. |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/23/11 at 17:16:19 looking real good. I like the color combo. Its been a long time coming waiting to see this. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/24/11 at 06:47:54 I hate Thanksgiving day. The only businesses open are grocery stores, gas stations and fast food joints, none of which sell deep 10mm sockets. Then tomorrow means fighting through Black Friday madness just to run ordinary errands. Guess I'll need to do something else. Sigh. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/24/11 at 09:36:38 Errrgh. You need to remove the whole headlight bucket in order to remove the light. And the bolts are about three times longer than they need to be. Stupid design, Suzuki. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/24/11 at 12:19:33 Who says you can't use woodworking tools on machines? http://i280.photobucket.com/albums/kk182/motobuddha/31f06f12.jpg I'm using some of the epoxy Ryca supplied with the kit. It's supposed to stay rubbery instead of going hard and brittle. So I'll see if the pucks stay on. I'll also be greasing them for easier sliding. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/25/11 at 11:27:52 I decided I'd rather have the neutral light in the idiot light cluster than the high beam light. No problem, just plug the neutral light into the center hole. But where to put the high beam light? On the headlight bucket, of course. So I got a small LED module at Radio Shack. I would have preferred blue, but they didn't have it in the store. http://i280.photobucket.com/albums/kk182/motobuddha/10d55efd.jpg I drilled a hole in the bucket where it's visible between the gauges. Now I just need to wire things up. http://i280.photobucket.com/albums/kk182/motobuddha/494616f8.jpg |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 11/25/11 at 11:39:02 CONGATULATIONS! She looks mighty sharp... And at least you're in Charlotte, where even if it is the dead middle of winter, you'll probably still get to ride it when it's finally ready!! |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/25/11 at 13:29:40 I like horns that honk instead of beep, but I don't like them hanging out in the open. The tail hump seemed like a natural spot. So I bent up a piece of aluminum and did some drilling and painting. Then I extended the wires to the rear. http://i280.photobucket.com/albums/kk182/motobuddha/40b4f3cc.jpg http://i280.photobucket.com/albums/kk182/motobuddha/60451aa9.jpg |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 11/26/11 at 10:57:43 HEY BUDDAH, I know you posted somewhere that you have an 18" shouldered rim on the front there. Do you happen to know what the measurements for your spokes are on that wheel? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/26/11 at 12:22:31 No. I just sent the rim and hub to Woody's Wheel Works and had him figure everything out. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/26/11 at 12:28:32 Only a couple of dozen small things on the checklist. For example, in the photo, the side cover is held on with electrical tape, and I need to borrow a friend's chain tool so I can get that mounted. I spent the day with small but tedious wiring things, like the speedo and tach, the front turn signals, shortening the cable to the starter, adding spacer foam for the compact battery, and doing some final rearranging of the harness. And taking pictures, of course. http://i280.photobucket.com/albums/kk182/motobuddha/304142bc.jpg http://i280.photobucket.com/albums/kk182/motobuddha/2480e435.jpg |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 11/26/11 at 12:39:03 THANKS BUDDAH! I figured that was the case, but thought I'd ask. I'm sending mine down to a guy in Mass; he wanted me to ask, but he knows what he's doing and he can figure it out for himself too. That's what I'm paying him for!! 082A312A073021212D24450 wrote:
|
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/26/11 at 13:45:31 What kind of mirrors are those? Looking for something like it on another build. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/26/11 at 13:52:43 I can't remember the brand (BikeMaster?) but I searched the hell out of the internet for mirror options. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/27/11 at 13:55:29 Are there any engine cover bolts on the alternator side that require the black nylon washers? I have three of them sitting here, I know the ones on the clutch side are in place, and I can't find any reference -- either in the Clymer manual or the online parts microfiche. (Or I'm stupid and can't see it.) |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 11/27/11 at 14:46:11 4F6D766D407766666A63020 wrote:
maybe something like this could work: http://www.lloydvintage.com/indicator-led-blue.html |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 11/27/11 at 15:05:57 43617A614C7B6A6A666F0E0 wrote:
nope, nada, none. no oil gallery bolts. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 11/27/11 at 16:58:04 You have as many spares as you need for the other side. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/27/11 at 19:34:18 Thanks, guys. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/28/11 at 09:36:17 Well, I think I have the electrical system all back in place, but since this magical, invisible electricity thing is outside my comfort zone, I've resisted connecting the battery. The coward in me is afraid I'll fry something, like the black box. Or, more frustrating, that it just won't work and I won't know why. |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 11/28/11 at 11:18:06 6B495249645342424E47260 wrote:
But after al this time, aren't you just DYING to fire it up?? We're all waiting on the edge of our seats!!! |
|
Title: Re: The Project: Phase 4 Post by SurfJunkie on 11/28/11 at 12:11:38 Worst case is you pop a fuse or the bike wont start. DO IT ! |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/28/11 at 14:31:55 Darned Mondays. I went to the motorcycle shop to get fork oil and brake fluid, but they were closed. |
|
Title: Re: The Project: Phase 4 Post by jandaso on 11/28/11 at 14:36:01 that happened to me too. i just got back from my mechanic to get the head to start painting that since im almost done with the whole motor so i feel your pain |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/28/11 at 17:14:46 I had the same anxiety when I first turned my ignition on. Heard a big pop and blew a fuse. Turned out I had one of the connections hooked up wrong. Not a big deal but certainly makes you nervous hearing the fuse pop. I say go for it. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 11/28/11 at 21:33:56 Do you have any pics showing how you routed all the wiring? |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/29/11 at 05:54:35 79474C515C515C3E0 wrote:
It ain't pretty, but here it is. I was more concerned with tucking things out of sight than making the unseen stuff look good. I've shortened the wiring from the controls and run some new ones for a high beam light in the headlight bucket, a horn in the tail, and power for the gauge lights. http://i280.photobucket.com/albums/kk182/motobuddha/4d4e1095.jpg http://i280.photobucket.com/albums/kk182/motobuddha/20d9ba45.jpg http://i280.photobucket.com/albums/kk182/motobuddha/4e72ff8d.jpg http://i280.photobucket.com/albums/kk182/motobuddha/10b934b3.jpg http://i280.photobucket.com/albums/kk182/motobuddha/72b9e5ad.jpg http://i280.photobucket.com/albums/kk182/motobuddha/ebff9917.jpg |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 11/29/11 at 06:46:09 Thanks LARGE!! That is exactly what I need! This probably saves a whole evening (two if you consider I'm doing two RYCAs). How close does the tank come to the coil? These two bikes have a 1/4" variation between them on the coil mounting holes. (Apparently the statements about lack of precision on the Suzuki production line are true) It looks from your pics like the coil is actually touching the tank mount rubber. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/29/11 at 07:17:32 It takes some extra struggling to get the tank on past the coil the way it is now. I'm going to see if there's room to be had between the back if the coil and the frame. If so, I'll shorten the hexagonal standoff thingy. About 1/8" would help. Update: There was still space between the coil and frame, so I ground down the standoff. It does help. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 11/29/11 at 07:55:25 The coil on my bike is on the left side. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/29/11 at 08:12:19 515A5A535F50514B4A3E0 wrote:
That's the stock location, but as part of the Ryca conversion, it get's moved to the right side. That because of the way the tank and mounts get modified. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 11/29/11 at 10:17:28 From following this and other Ryca threads it seems to me that this is a "we supply the parts and you make 'em fit" kind of kit. For what they charge you should be able to bolt it together without all the hassles you guys are having. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 11/29/11 at 10:30:03 I haven't had any problems with the Ryca parts, except the way the battery box and supplied air filter don't really work together. The tank, seat and all the other parts work perfectly, once you get over any individual lack of understanding and skills. The thing is, there are slight variations between the bikes as Suzuki builds them. For example, the wiring harness has changed several times and there have been two different sets of bars, which means different length wires. And there is sloppiness in frame tab locations. I think solving little problems adds to the challenges and fun of working on a project. |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/29/11 at 16:23:02 65475C476A5D4C4C4049280 wrote:
agreed buddha. I am getting tired of these people posting comments implying that the bike should just bolt together. We are talking about a bike that has been produced for 15 years or so (maybe more or less) but obviously tooling and tolerances are going to change from year to year. RYCAs instructions are good, their videos are good. I have posted this before- if you feel like it should just bolt together in an evening, then maybe you should pay the $500 to have RYCA put it together for you, because you probably shouldn't be doing the conversion anyways. |
|
Title: Re: The Project: Phase 4 Post by arteacher on 11/30/11 at 06:00:26 Thanks for your polite reply, Buddha. Sbaugz, I don't recall seeing a whole lot of posts (or any) complaining about the difficulty of building the kit, so you must tire easily. ;) I have no interest in building one myself, or having Ryca build one as I think they are very pretty, (especially Buddha's), and very impractical. |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 11/30/11 at 18:50:07 7F74747D717E7F6564100 wrote:
impractical sums it up for sure. uncomfortable is a good description too. but its also darn cool and gets tons of comments while riding it. And sorry to disagree, but over the past several months I have read lots and lots of posts here complaining about the RYCA build not being a simple bolt and go job. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 11/30/11 at 19:46:05 56474450425F250 wrote:
impractical sums it up for sure. uncomfortable is a good description too. but its also darn cool and gets tons of comments while riding it. And sorry to disagree, but over the past several months I have read lots and lots of posts here complaining about the RYCA build not being a simple bolt and go job.[/quote] I have mixed emotions about this,... well, let's say several thoughts. -- The kit is not as well thought out or manufactured as it should have been. -- That said, it is a pretty good effort for a couple of kids in California that bit off way more than they could chew. -- I was kidding myself when I let Ryan bu***hit me into believing an LS650 could be transformed into a CS-1 in a few weekends. -- If he would have said up front something like, "We'll give you 95% of the pieces you'll need to put the thing together, and most of those pieces will require "minor fitting" (yeah right)".... "Oh, and you might have a few safety issues and legal issues to handle, if you feel like it." (spokes bent, smog problems) I probably would have done it anyway. -- My main complaint is with myself. I just should have had my eyes wider open. The bike is so cool, and I have always had an optimism about these kinds of projects (building gyrocopters, hot rods, engine swaps, etc.). In each of those projects I end up with the same feeling,.. jeeez, I shoulda known. In a few weeks ours will be done, and we'll be glad. I can't wait to take it to places where there will be folks that'll know it is something special. Impractical schmactical!! Who cares?! You don't get involved with a bike like this if it is your only transportation, or if you ever think you're going use it to bring back a sack of quickrete from Home Depot. Bringing up the obvious fact a CS-1 is impractical is like flying around in January on an open-framed gyro and complaining about the cold. Yes it is not a simple bolt and go job. The signs were there; I should have known. With every project I have done like this, the signs were there; I should have known. But I do it anyway! AND,... I'm going to be quite pleased with it, and with myself. |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 12/01/11 at 09:21:09 Given that this is Buddah's build thread, I think it's worth pointing out that his bike, among any of the other RYCA kit bikes I have seen here, is perfect proof that the kit is simply what you make out of it... Not one of them is the same because every one wants theirs done in their own way. Sure, it would be cheaper and easier by a mile to just pay the $500 and have it built, but then they would all be the same and that's not the point of doing a project like this at all. I would have gotten the kit myself, except that my friend who is helping me out is a professional bike builder, and he wanted to do something totally custom from the ground up, based on a lot of Ryca's principles. I could never do that on my own, but the kit, even with its quirks, I think I could handle. Virtually every bike I have owned I have installed aftermarket parts onto, and rarely do they fit like a glove, or exactly like the instructions say, even if they are purpose built for that exact model. It's the nature of the beast, and if you don't want to wrestle with that beast, Ryan is willing to do it for you! |
|
Title: Re: The Project: Phase 4 Post by sbaugz on 12/01/11 at 09:39:30 69585C5F524A510C0E3D0 wrote:
well said |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/01/11 at 11:00:08 I'd say 90% of the challenges I've had with this project were because of things I wanted to do differently, like the chain conversion. And, like I've said, I enjoy solving problems. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/02/11 at 10:52:26 A little something from across the pond. http://i280.photobucket.com/albums/kk182/motobuddha/1a9774d6.jpg Now I need to make up my own quasi-official looking art to go in it. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/02/11 at 15:02:42 My buddy brought over the chain tool. http://i280.photobucket.com/albums/kk182/motobuddha/a4232e9e.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/03/11 at 10:54:05 Back from Kinko's for a printout and Ace Hardware for a bolt and nut. http://i280.photobucket.com/albums/kk182/motobuddha/1dafb15f.jpg http://i280.photobucket.com/albums/kk182/motobuddha/f2b05959.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/03/11 at 13:40:34 Since I'm not a machinist, this is my solution to shoe-destroying knurling on the shifter. Heat shrink. http://i280.photobucket.com/albums/kk182/motobuddha/7b9a5af3.jpg |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 12/03/11 at 16:12:55 73514A517C4B5A5A565F3E0 wrote:
The chain looks awesome! Nice job... How does the clearance over the swingarm look now that it's on there? Also, Kudos to your judicious use of heat shrink... Looks as good as I'm sure it works... |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/03/11 at 18:19:53 This is with no weight on the bike. http://i280.photobucket.com/albums/kk182/motobuddha/5d5d135b.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/05/11 at 09:00:50 After a year of looking at the engine without the sprocket cover, and that becoming the new "normal" in my mind, the engine suddenly looks fat now that the cover is back on. So I've been thinking of trimming it like this: http://i280.photobucket.com/albums/kk182/motobuddha/38fd8983.jpg But I'd want a good machinist to do it, not me with my handheld angle grinder. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 12/05/11 at 09:27:42 I think that would look just fine AND satisfy the need to protect body parts from the pinch-point, |
|
Title: Re: The Project: Phase 4 Post by Serowbot on 12/05/11 at 10:00:37 02203B200D3A2B2B272E4F0 wrote:
I like it!... Hacksaw and a file,... easy as toast... ;)... |
|
Title: Re: The Project: Phase 4 Post by EJID on 12/05/11 at 10:04:25 7563746971646972060 wrote:
I like it!... Hacksaw and a file,... easy as toast... ;)...[/quote] I don't know, I tend to burn my toast :-[ I would leave it to a machinist with the quality of the work on MB's bike. (Looking forward to the finished product) |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 12/05/11 at 10:10:23 I burn my toast too, so I understand your hesitation, but I do really like the idea, and I must agree; you've spared no expense or extravagance on this beast, and if you know someone good, this will be a no-brainer for someone who knows what they are doing... Should be well worth the few dollars it will cost. You want it to look like it came that way from the factory... |
|
Title: Re: The Project: Phase 4 Post by RidgeRunner13 on 12/05/11 at 11:20:46 I would use a uni-bit to drill a hole where your almost 90 degree angle is, the bigger the better. Then just use a hacksaw or sawzall (my favorite) to cut to the edges of the hole. A little work with a file & some sandpaper to smooth it up & you're done. 8-) Yesterday I couldn't even spell machinist, now I are one. ::) ;D |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 12/05/11 at 11:44:05 Mark it, then tape the line, then drill to create the radiius, then cut & leave some room, then use a grinder. If you can mount the grinder & set the switch to keep it running, then you can make the straight lines, a round file for the radius, Chainsaw sharpening files are good for delicate work, Some machinists will do a little job like that for almost nothing,, tho, so do walk in a few shops & show them what youre trying to do, being on the bike will only increase your odds of getting it done for free.. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/05/11 at 12:47:13 But there's also the matter of the webbing on the back side. It should be milled off first. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 12/05/11 at 13:11:12 I might try something like this: (your .jpg is shown in the bottom pic for easy comparison) http://i258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Motorcycle/Miscellaneous/motobuddhasidecover01a.jpg http://i280.photobucket.com/albums/kk182/motobuddha/38fd8983.jpg Cut it like you suggest, plus reshape the top to be nearly parallel with the top of the chain (belt for me), and fill in the two cosmetic slots. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/05/11 at 13:14:24 I like the look of the slots. And they make it lighter. |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 12/05/11 at 15:02:45 03213A210C3B2A2A262F4E0 wrote:
To each his own. I don't like the look of the slots, and the way they line up with the top of the cover, and the way the top of the cover sticks way up away from the belt. It makes it look like the cover was made to fit something else,.. which in the case of a CS-1, it sorta was. Maybe I'd like the slots if they were lined up with the other visuals on the bike. Yeah, that's it!,... fill in the slots, then cut new ones that flow better with the looks of the mechanical stuff on the left side of the machinery! |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 12/05/11 at 18:48:49 I have to agree, at least partly with GYROBOB here. I was looking at the top part of the cover myself, wondering how I could lower the angle, but remember; that folds over and covers the top of the belt/chain, so if you cut that off, are you going to then weld on a new top piece? I think that might be structurally important; having that angle and the webbing on the back side that supports it. By the time you do all of that, and weld in those slots, sand it all back smooth, and then re-cut new ones, would it make sense to have someone make a whole new cover from Fiberglass? I know my project is basic enough that I probably won't mess with it myself, but for you Buddah, given how far you've taken this thing already, it seems like it's worth looking into... I can't wait to see what you decide!! |
|
Title: Re: The Project: Phase 4 Post by Gyrobob on 12/06/11 at 06:47:43 714044474A52491416250 wrote:
Yes, welding on a new top piece would be required. This mod would be out of the question if you did not have a Mig or Tig welding capability available. I wonder, though, if some of the systems that "braze" aluminum might work? I've seen guys at expos and fairs, etc., use a torch to do what looks like soldering or brazing two pieces of aluminum together with some sort of aluminum-friendly rod,.. making it look as easy as soldering copper with lead solder. |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 12/06/11 at 06:54:12 0E303B262B262B490 wrote:
WOW! That must take some kind of amazing skill, or at least some trickery I don't know about. I'm a barely functional welder as it is, but I've always been told that Aluminum can't be welded with a torch because it dissipates heat so quickly that by the time you melt the part you are trying to weld, the whole thing slumps into a puddle. But yeah, I suppose if you used a cooler temperature torch, you could probably solder it together in some form? Definitely going do some research on that idea. It could make sometimes costly repairs to engine cases a lot more manageable... even if you just find the right guy to do it for you! ;) |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 12/06/11 at 07:12:03 HF has the stuff you need. aluminum welding rods, I've posted the link before, but this time you look it up. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/06/11 at 13:08:22 A double good thing -- I needed to tighten my oil drain plug but didn't have a 17mm combination wrench. (There wasn't enough room between the plug and the frame for a socket wrench.) So I went over to Lowe's. Well, whadda ya know, they've finally started selling individual wrenches and sockets. That was the first good thing. The second was that they had a stubby 17mm combination wrench. Perfect for the limited space under the bike. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/06/11 at 15:08:46 Win two, lose one. I was filling and bleeding the front brake and discovered the master cylinder wasn't pumping. So I figured I'd take out the piston and check the seals. Well, in order to get at things, I had to destroy the rubber boot. Then my circlip pliers wouldn't fit into the tunnel the clip is burried in. I worked at it with an awl, pretty much bending it out of shape just before it went flying who knows where. But the piston came out. Awful dirty in there. Since I had to get a new boot and clip, I figured I might as well get a new piston and seals (since the seals don't come separately). Oh well. |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 12/10/11 at 10:26:41 guess whats on its way: http://i1226.photobucket.com/albums/ee419/rpnsht/photo7.jpg |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/10/11 at 10:54:06 Yay! Christmas! Were you able to clean up the scratches on the front? |
|
Title: Re: The Project: Phase 4 Post by RpNSht on 12/10/11 at 17:07:25 52706B705D6A7B7B777E1F0 wrote:
i think bead blasting is your best bet |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/17/11 at 13:17:01 Well, this sucks. I finally got all the electrical bits together, connected the battery, turned the key to ON, pulled in the clutch, pushed the decompression lever, hit the start button and....... Nothing. Kill switch in the correct position? Try it the other way? Still nothing. So many things that could be the culprit. Sigh. |
|
Title: Re: The Project: Phase 4 Post by teabowl13 on 12/17/11 at 16:01:06 Grrrr.... Wish I could help you... I'm totally electrically retarded.... Fear not. It will come alive!! |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 12/17/11 at 17:29:38 This may help... http://www.savageriders.com/verslagen/images/'96-'03Startingcircuit.jpg Start at the starter switch and follow the juice to the starter. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/17/11 at 18:11:10 Yeah, I have the manual. And a voltage tester. I'm just not very methodical and patient. |
|
Title: Re: The Project: Phase 4 Post by crackmonkey on 12/17/11 at 19:45:41 try kicking it. It won't solve anything but might make you feel better until you realize you just jacked your new paint up. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 12/17/11 at 21:36:32 Of course you had visions of sitting on your pretty new bike & hitting the GO Button & the Angels in Heaven all singing & the bike starting right up.. Welcome to reality.. Youve been all over it, messing with everything there is, odds of it NOT having a problem or 2 are slim. This is normal., youve gotten to here, youll win itl. Its time to Get methodical & learn some patience. Its all part of growing up. Anyone can just get older. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/18/11 at 05:26:16 Actually, I would have been stunned if it had cranked right up. Yes, I've had everything apart, I've fiddled with some of it, and electrical systems are far from my strong point. I've never claimed otherwise. |
|
Title: Re: The Project: Phase 4 Post by justin_o_guy2 on 12/18/11 at 06:23:42 I know youve readily admitted your lack of ability in the electrical department. I totally understand. I dont like messing with that styuff either & Im far from a pro at it. Ive seen guys I swear they could see the juice flowin in the wires & knew right where the problem was.. Thats not me, but, the only way to win is, either have a good memory & not get confused or use a notebook, start checking for power in places you know its supposed to be, Check grounds, I like the notebook so that if I dont win quick I can walk away & come back & not have to start over. The AF taught the 1/2 split troubleshooting method. Check signal at source, check signal where its supposed to be. If its not there, go 1/2 way back to source & check. If its not there, go back another 1/2 way, if it is, go forward 1/2 way, check, It'll hunt down pretty quick that way, A test lite & an ohm meter & a notebook & wiring diagram & youll win,. |
|
Title: Re: The Project: Phase 4 Post by MotoBuddha on 12/18/11 at 06:46:12 A stupidity double check: the red cable goes to the + terminal of the battery, right? |
|
Title: Re: The Project: Phase 4 Post by dasch on 12/18/11 at 07:21:32 5E4147405D5A6B5B6B53414D06340 wrote:
How many halfs you have in one whole?? ;D |
|
Title: Re: The Project: Phase 4 Post by verslagen1 on 12/18/11 at 09:18:58 usually ;D |
|
SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved. |