SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> My trip down RYCA lane
/cgi-bin/YaBB.pl?num=1375238528

Message started by Gheorghe on 07/30/13 at 19:42:08

Title: My trip down RYCA lane
Post by Gheorghe on 07/30/13 at 19:42:08

Hello all,

I haven't posted on here much but I have been a long time lurker. Up till last year I really didn't know much about the Savage/S40/LS650 but with the help of this site I have become very familiar with this little bike. I must admit that what had me looking at the S40 was the the very first RYCA conversion I had seen which was done by member "RpNSht". As soon as I saw his bike I knew that I wanted one. Long story short, I started my search early this spring and this is what I bought on April 27th:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Firstday3.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Firstday3.jpeg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Firstday1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Firstday1.jpeg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Firstday4.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Firstday4.jpeg.html)

Yes, windshield, saddlebags and all the fixins that would need to be taken off in order to make it leaner and meaner. ::) Bike is an 06, has 3,300 miles, very clean and two previous owners. It looks like it was very well taken care of, it runs pretty good, does have a gnarly back fire ...........and is exactly what I wanted.
A few minutes after I got it in the garage:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Prestrip1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Prestrip1.jpeg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Prestrip.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Prestrip.jpeg.html)
8-) 8-)
Lighter and Better ;D

More to come.............

Title: Re: My trip down RYCA lane
Post by Gheorghe on 07/31/13 at 09:39:35

So the goal for the RYCA build is clean and lean. I want to get rid of all unncessary wires tabs and holes that are not used. This also included smoothing everything out.

A lot of the inspiration for this bike came from the original RYCA bike that the company Built:
http://thekneeslider.com/images/2010/05/ryca-cs1.jpg

and two previous builds that many people may have seen. Thank you gents!! The first is RpNSht --->http://suzukisavage.com/cgi-bin/YaBB.pl?num=1304297812/0#0/
and the second is from Gyrobob ---http://suzukisavage.com/cgi-bin/YaBB.pl?num=1304722902/0

I did a lot of the same tricks that they did in their builds and some of my own.

The RYCA Kit was orders on April 29th and consisted of:
-Black Vinyl Seat
-Standard Chrome Shocks
-Unlaced ploished rear rim
-spedo and tech

I planned on running Firestone Champion tires as in the original RYCA build but after doing some research and finding out that they may not be the best for handeling I decided on running Dunlop K70s instead. Also, I modified my own swing arm.

I sent RYCA my tank on May 1st

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/MirrorMount3.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/MirrorMount3.jpeg.html)

And then the fun began...

Title: Re: My trip down RYCA lane
Post by Gheorghe on 07/31/13 at 09:58:00

So while I was waiting for the RYCA parts to come in I decided to keep myself busy.
The first things I tackled were the mirror mounts. I planned on running bar end mirrors so no need to things sticking out unused.
This is what Mr. Grinder and I started with:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/MirrorMount2.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/MirrorMount2.jpeg.html)

I was hoping that the perch would have a blind hole for the mirror mount and that simply grinding it off would reveal a smooth surface but that is not the case........oh well
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/MirrorMount4.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/MirrorMount4.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/MirrorMount5.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/MirrorMount5.jpeg.html)
So to close the hole and keep things smooth and seamless, I decided to use a bolt to plug the hole...but how do you make it so the bolt doesn't move?? Loktite is an answer but I was afraid that baking the part during the powder process might weaken the bond and later come undone. A beer later, I figured that I'd use a bolt of the same diameter but different thread pitch and just "strip the threads". So I got this:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/MirrorMount7.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/MirrorMount7.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/MirrorMount6.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/MirrorMount6.jpeg.html)

By this time I started using Mr. File and Mr. Sand paper. The intent wasn't to polish the piece as the powered coat will smooth things out.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 07/31/13 at 10:26:17

By the way, all of the parts that are coming off the bike are for sale:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1370874839/0#0

So to continue smoothing things out, I got a little crazy with the wheel hubs as well. Most people will probably never notice this but the casting marks were bugging me and I figured that if I have the time (was still waiting for RYCA parts) and things will be powder coated, why not..

Front:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/FrontHub1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/FrontHub1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/FrontHub.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/FrontHub.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/FrontHub1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/FrontHub1.jpeg.html)
A little filing a little sanding and voila

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/FrontHub5.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/FrontHub5.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/FrontHub4.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/FrontHub4.jpeg.html)
Rear:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics385.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics385.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics389.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics389.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics388.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics388.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics396.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics396.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics398.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics398.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics397.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics397.jpg.html)
The material is all cast aluminum and is very soft so all the work is very easy, polishing might take a little more but the hubs are destined for powder so no need.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 07/31/13 at 11:33:26

So I continued to blow the bike apart for more preparation:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics399.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics399.jpg.html)
YEY!

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics400.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics400.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics421.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics421.jpg.html)

The parts blanket getting full
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics378.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics378.jpg.html)

Title: Re: My trip down RYCA lane
Post by LANCER on 07/31/13 at 13:30:44

I can see your first problem already; you are TOO organized. ;D

Title: Re: My trip down RYCA lane
Post by WD on 07/31/13 at 14:14:05

373A35383E29696C5B0 wrote:

I can see your first problem already; you are TOO organized. ;D

You are supposed to work under a tree in the front yard. How else will you learn the "joy" of hunting little bitty rusty fasteners in grass, sand and gravel?

;)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/01/13 at 06:06:32

697A3E0 wrote:

[quote author=373A35383E29696C5B0 link=1375238528/0#5 date=1375302644]I can see your first problem already; you are TOO organized. ;D

You are supposed to work under a tree in the front yard. How else will you learn the "joy" of hunting little bitty rusty fasteners in grass, sand and gravel?

;)
[/quote]

HAHAHA, I am a bit OCD when it comes to cleanliness and organization even though my garage is nowhere as clean as it should be.

But let me tell you, the joys of having a little grommet or spring fly off in the stratosphere right out of your hand doesn't diminish when you are on concrete either. I can't tell you how many times my girlfriend or someone else would walk in the garage to find me on all fours in a corner staring at the ground :o :o "But…. But… I'm looking for the little widget!!!"

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/01/13 at 06:38:26

Electrical:

I wanted to run a very clean and efficient wiring / electrical system. That to me means no cutting things off just because I am eliminating a switch. What I wound up doing is actually pulling the entire harness apart and eliminating entire circuits. To some people this may seem like a hard job but if you take your time it really is not. The electrical system on these bikes if very simple and if you have the service manual it is even easier. The hardest part to me was un-taping the harness to expose the wires.

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics434.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics434.jpg.html)

So the first thing was to eliminate the entire Decompression Solenoid along with the Solenoid Module and all of its wiring and connectors. To do this, and still be able to start the bike, you have to solder the power wire that would normally go in to the module to the rest of the starter system circuit, but again it is very easy once you see it in front of you, eliminating this system also eliminates one of the two 20Amp fuses in the system, this can be repurposed for a phone charger or GPS???? I didn't do anything with it :P.

This is the thing I wanted to eliminate,
http://i233.photobucket.com/albums/ee113/gheorghe19/Presentation1.jpg (http://s233.photobucket.com/user/gheorghe19/media/Presentation1.jpg.html)

with a little work you wind up to this:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics442.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics442.jpg.html)
Then this:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics443.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics443.jpg.html)

But I think it is much cleaner and in the end you pull out complete circuits that you do not need.

Decomp Circuit:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics433.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics433.jpg.html)

Side stand switch and circuit:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics444.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics444.jpg.html)

END RESULT Much cleaner and simpler.

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics438.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics438.jpg.html)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/01/13 at 07:02:33

Swing Arm:
Another job I wanted to do on my own was to modify the swing arm. The two reasons for this were that I am running a Dunlop K70 tire so it is taller than 26" which equals a no bueno for the swing arm clearance. The second is that I wanted to shave it completely smooth (including the passenger foot peg mounts.......both of them) more on the last later.
So here is me and my pops at the cutting table:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics450.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics450.jpg.html)

UH-ohhhh

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics454.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics454.jpg.html)

Dunlop states that the diameter of their 4.00-18 rear tire (which is what I am running) is 26.73" so I put a little fudge factor in there and said that my tire will be 27.5" when all is said and done. Took half of that and measured from the axle (full forward position) to the swinger. Then I started cutting ;)

Time to put it back together:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics456.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics456.jpg.html)

I have a friend that is a crazy good welder and he decided to get carried away with the shape of the swing arm. So in an afternoon, this is what we wound up with:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics427.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics427.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics522.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics522.jpg.html)

Finished result:[

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics530.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics530.jpg.html)

I am very happy with it as I know it will be a lot stronger than before and to me, it looks killer.

Title: Re: My trip down RYCA lane
Post by Dave on 08/01/13 at 10:01:50

You are well on your way - the fitting of parts takes a good bit of time but is very rewarding as it starts to look like a bike again.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/21/13 at 10:32:30

Frame cutting, I decided that since I am using the hand decomp lever, I no longer need the unused middle bracket on the left side of the bike........ so I took it off

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics459.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics459.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics460.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics460.jpg.html)
No More ;D
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics457.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics457.jpg.html)

While I was cutting and grinding, I also decided to polish this little guy

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics461.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics461.jpg.html)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/21/13 at 10:49:04

One other thing that I copied from Rpnsht was the top triple, I didn't want to have the holes from the handlebar isolators left in so a little machining and care took care of them....

One thing to note, if anyone cares, is the triple is made of the main piece and two small collars that are pressed in to it from the top to form the isolator mounting area for the handle bars. Those collars can be pressed out, here is what I mean, top of triple with top collars pressed out:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics445.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics445.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics446.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics446.jpg.html)

And done:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics495.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics495.jpg.html)
I still wanted to mount the gauges in the same location so the plugs that were used to fill the holes had blind holes drilled on the bottom and tapped to 10mm

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics501.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics501.jpg.html)

Also, to have a belt and suspenders approach to the triple, a small roll pin was drilled and pressed on the bottom through each plug. Sorry for the blurry pic but the black dot is the roll pin that goes through the plug, it is drilled in the remaining lip on the bottom of what used to be the isolator hole. The picture tells the story.
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics498.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics498.jpg.html)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/21/13 at 11:01:13

June 12th: this showed up

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics473.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics473.jpg.html)

Yup, entire RYCA kit. Thanks to RYCA for being a cool company and for the quick turn around. Ryan is super cool to deal with.

If anyone was interested in seeing the exact differences between the tanks, here is a before and after RYCA treatment:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/Tank2.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/Tank2.jpeg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/Tank1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/Tank1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/Tank3.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/Tank3.jpeg.html)

After:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics554.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics554.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics553.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics553.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics551.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics551.jpg.html)

I will be using a "pop up" gas cap so the entire origianl gas cap will be cut out and a new bung will be welded in

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/21/13 at 11:10:46

The only way to make a bike nice and clean is to take care of the little things, what I mean by that.........Powder Coat!!! I live very close to, what I consider to be a very good powder coating and ceramic coating facility---------QC Coatings. A bunch of cool guys whom love anything automotive, if you live in Michigan and want something done right, I cannot recommend these guys enough.
I dropped off 13 pieces:
The switch control housings (4 individual pieces)
Front hub
Rear Hub
Clutch Perch
Clutch lever
Brake Lever
Frame
Swing arm
Upper and lower tripples

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics502.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics502.jpg.html)

This is what came out.....Black and shiny

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics546-1.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics546-1.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics549.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics549.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics550.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics550.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics547-1.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics547-1.jpg.html)

Title: Re: My trip down RYCA lane
Post by Dave on 08/21/13 at 12:18:08

Well that surprised me.....I thought you were getting the aluminum bits smooth so you could polish them.

I didn't anticipate the shiny black!

Title: Re: My trip down RYCA lane
Post by JenRides on 08/21/13 at 12:29:56

so exciting! can't wait to see the progress unfold more :D

Title: Re: My trip down RYCA lane
Post by WD on 08/21/13 at 15:31:41

Nice! Full or partial chrome and polish delete? I'm likely going with full chrome delete on mine, can't stand that stuff.

Title: Re: My trip down RYCA lane
Post by ToesNose on 08/21/13 at 15:37:00

Your project is really coming along nicely, it's plain to see how much thought and effort you are putting into it to get everything just right. ;)

Looking forward to seeing the bike all done for sure! :D

Title: Re: My trip down RYCA lane
Post by gdrseeker on 08/21/13 at 16:33:45

I like it so far. I look forward to following this thread.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/22/13 at 07:46:07

102B2631202C37312A222F30430 wrote:

Well that surprised me.....I thought you were getting the aluminum bits smooth so you could polish them.

I didn't anticipate the shiny black!

I was thinking about polishing at first but then I thought about striking a balance between black and polish. I don't know if it is for everyone but the rims will be polished and the hubs are black....
I also want the paint on the tank, seat and sides to be mainly black as well. We'll see how it turns out, if it is too much one way or the other I will change it over the winter

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/22/13 at 07:47:52

3724600 wrote:

Nice! Full or partial chrome and polish delete? I'm likely going with full chrome delete on mine, can't stand that stuff.

Thank you very much!
Yeah, I am not too big on the chrome myself, the only non powder/paint bits on this bike will be polished

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/22/13 at 07:49:29

467D77615C7D6177120 wrote:

Thank you very much for the compliments, I loved this project so far.

Stay tuned for more updates.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/22/13 at 08:03:08

I kept reading that the stock fuel cap is not the more reliable unit out there so I decided to see if I could find a better solution. What I found is this guy:
http://www.meancycles.com/store/parts/view.cfm?partID=214609
You get a bung as well as a vented pop up cap. I decided to give it a whirl...

Stock Bung out
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/CopyofIphonePics503.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/CopyofIphonePics503.jpg.html)

Cleaned up the opening:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/CopyofIphonePics525.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/CopyofIphonePics525.jpg.html)

Used some spit and presto:

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics526.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics526.jpg.html)

Title: Re: My trip down RYCA lane
Post by Ralph_86-Savage on 08/22/13 at 08:58:24

I'm LOVING this thread. This is better than the original American Chopper show.

Title: Re: My trip down RYCA lane
Post by Dave on 08/22/13 at 09:33:16

Gheorghe:

I am not sure how you are going to attach the bung.....but don't underestimate the power of acid flux and solder. With the low heat there will not be any warping, and it will hold plenty strong for a fuel bung and cap. It also makes a nice fillet at the joint.

I put my new petcock mount on my tank with solder.....lots of vintage tanks only used solder for the seams. The metal has to be clean, and you must use Acid flux on steel.....not Rosin or the flux you use for copper or brass pipe.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/23/13 at 04:21:41

Hi Dave,

Thanks for the heads up, I wish I would have known about this a little sooner because what I wound up doing is taking it to a local welding "expert" and had him TIG welded it. That was all good and well but he warped the tank a bit in one spot and I am generally unhappy with how it came out. I will be able to fix it with some body work (pull the metal back) and then smooth it with a tiny amount of body filler but still, I thought it would be smooth considering this guy supposedly builds tanks from scratch...
I will keep the soldering idea in mind for future builds though

I appreciate all of the positive feedback guys!!

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/28/13 at 05:19:47

Clip ons:
I directly stole a page from RpNSht on this one, right down to the hand grips. While the hand grips from RYCA are pretty cool I wanted the Driven hand grips seen here:
http://www.bikerperformance.com/images/products/driven-racing-sbk-streetbike-hand-grips-black-84407.jpg?width=800

The problem, as outlined by RpNSht, is that they are only made for 7/8" bars and the RYCA ones are 1".
One way to tackle the issue of making the grips fit is to soak them in boiling water to make then super soft. Another way, and this is what I did, is to use this stuff:
http://www.hondapartworld.com/image/data/Honda_SpryClnr_Plsh.jpg
Yes, Honda Spray Cleaner and Polish is a miraculous tool. Not only will it clean and polish your honda ;D it will also allow you to put on 7/8" grips on 1" bar. All I had to do is spray the inside of the grip, outside of the bar and push it on. It took a bit of force but it was not hard to do. The hardest part was the throttle because it is plastic and I didn’t want to break it but that wasn't super hard either. Sorry I do not have any pictures of this but the grips fit and look great. One thing I did on the throttle (sorry no pics of this either) is I ground down the ridges on the throttle that are used as locating/anti spin feature on the stock grips. I did this to make the throttle smooth and not be visible through the Driven grips.

DCC bar end signals:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics490.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics490.jpg.html)

These signals are made to fit both 7/8" bars and 1" bars but I didn't like the extra slop the shank had so I had my dad make me some nylon spacers to make them fit perfectly
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics491.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics491.jpg.html)

One other thing I wanted to do is use clip on mirrors. Unfortunately those only come in 7/8" flavor so we had to machine the end of the clip on to accept this:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics494.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics494.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics546.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics546.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics547.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics547.jpg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics548.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics548.jpg.html)

Title: Re: My trip down RYCA lane
Post by botticelli on 08/28/13 at 10:23:39

Great work, thanks for the step by step photos on this, I'm planning to do the same on my RYCA build this winter. Really looking forward to seeing how your project comes out.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/29/13 at 05:53:22

38352E2E33393F3636335A0 wrote:

Great work, thanks for the step by step photos on this, I'm planning to do the same on my RYCA build this winter. Really looking forward to seeing how your project comes out.

Thank you very much for the comments. I try to do my best and to possibly inspire other people as I have been inspired by the people on this board.

More work....

I kept reading that the little thumper will vibrate like crazy so one other thing I did to the clip ons is fill them with shot (shot peening material). Sorry no pictures but the idea of filling the bars with shot is to increase their mass and therefore decrease their vibration vrequency.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/29/13 at 05:56:19

Assembly:

I don't know if this was too easy or what, but putting this bike together took maybe 10 hours total from installing the engine in the frame to putting the clip ons on. I'll let the pictures do the talking.

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics559.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics559.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics560.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics560.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics562.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics562.jpg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics564.jpg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/IphonePics564.jpg.html)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 08/29/13 at 06:02:29

AAAANNNNDDDDD............. The moment of truth:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/th_IphonePics565.jpg (http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/IphonePics565.mp4)

Things left to do:

1)Biggie is paint but I want to ride it and see if there are any bugs in it
2)Install rear brake switch (with the smoothed swing arm I have to rig it a different way then RYCA suggested)
3)Install baffles in the mufler ala Gyrobob style
4)Build a fork brace of bob the stock fender, still deciding on this one
5)Ride the poop out of it

So far, it has almost 200 miles on it andall I can say is WOW!!!! ;D

My Ducati has been sleeping in the garage most of the time and the RYCA is now the primary terrorizer

Title: Re: My trip down RYCA lane
Post by LANCER on 08/30/13 at 05:21:46

5A7578726F7A75781D0 wrote:

This bike can bring on addictive qualities

Title: Re: My trip down RYCA lane
Post by ToesNose on 08/30/13 at 06:43:07

Great pics Gheorghe, it looks like the bike is coming along nicely. Looking forward to seeing it all painted up! :)

Title: Re: My trip down RYCA lane
Post by caseyLA on 08/30/13 at 12:12:13

I like #5 on the Things left to do list.

Title: Re: My trip down RYCA lane
Post by old_rider on 08/31/13 at 07:28:53

That's looking pretty flipping good!

Title: Re: My trip down RYCA lane
Post by Gheorghe on 09/03/13 at 04:31:33

Thank you for the comments guys. The bike is a lot of fun!! I love how it handles and how easy it is to ride. It now has 300 miles since the conversion and I absolutely love it. Today I will hopefully build the baffles for the muffler. Stay tuned for the pics.

Title: Re: My trip down RYCA lane
Post by babyhog on 09/03/13 at 12:28:31

Cute as the bumps on a pickle... :)

So what are your paint plans?

Title: Re: My trip down RYCA lane
Post by splash07 on 09/04/13 at 06:03:29

Darn thing looks sweet, I am very partial to these little bikes and have been trying to figure out how I am going to afford one....ever.

Question; with the ryca design do you have to relocate the ignition to the speedo bucket, or can the ignition stay in its orginal location?

Title: Re: My trip down RYCA lane
Post by Dave on 09/04/13 at 06:09:34

The ignition switch is relocated to the speedo hole on the RYCA....as sort of a re-purpose of that hole in the tank. RYCA makes a panel that fits in the hole and it as a panel for the ignition switch and the turn signal, high beam and neutral lights.

The ignition switch has to be moved a bit from the stock location as it is where the side panels are located - but it does not have to be moved up to the tank if you don't want it there.

Title: Re: My trip down RYCA lane
Post by splash07 on 09/04/13 at 06:38:29

310A0710010D16100B030E11620 wrote:

sweet thanks

Title: Re: My trip down RYCA lane
Post by Gheorghe on 09/22/14 at 06:51:56

5679747E63767974110 wrote:

Things left to do:

1)Biggie is paint but I want to ride it and see if there are any bugs in it
2)Install rear brake switch (with the smoothed swing arm I have to rig it a different way then RYCA suggested)
3)Install baffles in the mufler ala Gyrobob style
4)Build a fork brace of bob the stock fender, still deciding on this one
5)Ride the poop out of it

Time to Bring this Thread back up for updates.

Not in order, but one of the items on the list was to build a fork brace...... that did't happen!
Instead, on went one of these things :o

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/TKatbrace.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/TKatbrace.jpeg.html)

I haven't put too many miles on it so I can't claim that it made a night and day difference but it sure didn't hurt anything

Title: Re: My trip down RYCA lane
Post by Gheorghe on 09/22/14 at 07:00:57

0728252F32272825400 wrote:

I have also installed a rear brake switch, combination of stock and some creative baracketing. As I have shown in my previous posts, I have shaved off the swing arm so RYCA's solution was not going to work anymore. I do not have pictures becasue it is fairly hidden but it works and works well ;D

The other big thing was the paint............so I decided to paint it flat black and highlighter green ::)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/TankMaskedoff1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/TankMaskedoff1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/TankMaskedoff.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/TankMaskedoff.jpeg.html)
Nice ey??
Well not really. I actually went with a very cool local painter http://www.michigancustomcycles.com/
He did a super job and was very reasonable. Only 5 coats of clear on this puppy :)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/TankPainted.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/TankPainted.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/SeatPainted.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/SeatPainted.jpeg.html)
And right when I brought the pieces back just sitting on the bike

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/BikeWithPaintedTins.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/BikeWithPaintedTins.jpeg.html)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 09/22/14 at 07:11:18

Now I am calling this bike "done"

I have not put baffles in the exhaust because I'm a bad person. To be truthful, it does not bother me, it is not super loud and when compared to some other bikes I encounter on the road (read Harleys) it is pretty tame.

Here is the bike fully assembled:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/back3quarterleft1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/back3quarterleft1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/back3quarterright1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/back3quarterright1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/leftside.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/leftside.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/leftrearupper.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/leftrearupper.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/rightside.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/rightside.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/bikeside1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/bikeside1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/back.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/back.jpeg.html)

Title: Re: My trip down RYCA lane
Post by Gheorghe on 09/22/14 at 07:18:49

One more about this, I wish I had taken the pictures in the same place but here is where the bike started and where it is now:

Before:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Prestrip1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Prestrip1.jpeg.html)

http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/S40Prestrip.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/S40Prestrip.jpeg.html)
After:
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/back3quarterright1.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/back3quarterright1.jpeg.html)
http://i233.photobucket.com/albums/ee113/gheorghe19/RYCA/leftside.jpeg (http://s233.photobucket.com/user/gheorghe19/media/RYCA/leftside.jpeg.html)

Title: Re: My trip down RYCA lane
Post by Dave on 09/22/14 at 09:37:04

133C313B26333C31540 wrote:

Now I am calling this bike "done"

Done....Pffffft! It is "substantially complete".

It looks great.....but you will find a thing or two you want to change as you ride it and gets some miles on it.

I found the rear tail light with built in turn signals to be horribly inadequate if you ride when the sun is shining....it will only be seen if folks are staring at it...it will not get their attention if they are not looking directly at you. I added a supplemental stop light under the fender that is a really bright Emergency Flasher LED, and I added bright yellow LED turns signals.....they see me now!

The rear tail light should be taken apart and sealed up tight with RTV silicone. After a couple of rides in the rain my tail light got wet inside, and a few weeks later it stopped working. My most recently purchased one had a red lense to better tie in with my red paint scheme, and I took it apart and sealed it up before mounting it. (I don't use tail light turn signals and have "real" turn signals).
http://www.ebay.com/itm/390676538747?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

If you get caught in the rain - you will get a face full of water without a fender. The first year I rode mine without a fender as I ran out of winter and did not want to spend good riding weather building a fender. The front tire throws water all over you, all over the bike....everywhere! The next year I built a fender....and it is better as it does not throw as much water onto the engine and wiring up under the tank. The bike still throws water in your face and up your backside....and on both feet. :-/

You might want to consider adding a "stop" for the rear brake pedal. Instead of the rear brake pedal flopping around, the stop allows you to adjust the vertical height of the pedal and the brake will work like it used to. Go to Post #26 in this thread and see how Gerry built his:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1385498224/15

You might also want to use some silicone or Beeswax or something on the seams in the seat. When that buggers gets wet it oozes water out onto your bottom for a long, long time......and gives you soggy shorts every time you sit down!

Have fun....and get ready to spend a lot of time talking to folks whenever you stop.....folks really want to know what it is!

Title: Re: My trip down RYCA lane
Post by Gheorghe on 09/22/14 at 10:11:33

576C6176676B70766D656877040 wrote:

[quote author=133C313B26333C31540 link=1375238528/30#43 date=1411395078]Now I am calling this bike "done"

Title: Re: My trip down RYCA lane
Post by Kris01 on 09/22/14 at 13:59:17

Am I looking at this pic wrong? I don't see how the stop works. The arm either moves the wrong direction to contact the stop or I'm missing something.

http://i669.photobucket.com/albums/vv55/lotus23bsr/Public%20Album/Ryca%20CS-1%20Build/9Th%20Installment/DSCN0874_zps6e455f29.jpg

Title: Re: My trip down RYCA lane
Post by Jeff71 on 09/22/14 at 14:43:57

I think it is sitting back on it so the lever cannot rotate backwards and reduce the tension on the brake rod.
Jeff

Title: Re: My trip down RYCA lane
Post by Dave on 09/22/14 at 18:32:07

The stop prevents the pedal from moving up too far, and it allows you to tighten the adjustment nut on the rear brake arm to set the pedal movement. All production bikes have a stop built into the system that limits the brake pedal movement up.....the RYCA kit does not provide this and it is a needed improvement.

Here is the brake stop I made for mine, maybe it will help you visualize this a bit better. The rubber tubing over the bolt keeps the brake pedal from making a clicking sound when the brake is released.
http://i49.tinypic.com/zty8lv.jpg
http://i47.tinypic.com/idtxl2.jpg

Title: Re: My trip down RYCA lane
Post by Kris01 on 09/22/14 at 19:59:06

Oh, I see now. Thanks!

You guys have some pretty good machinists skills.

Title: Re: My trip down RYCA lane
Post by Superxin on 02/10/15 at 06:49:58

HEY[ch12289]
how long your rear wheel wire[ch65311]

Title: Re: My trip down RYCA lane
Post by Dave on 02/10/15 at 08:33:11

2230203A3520580 wrote:

HEY[ch12289]
how long your rear wheel wire[ch65311]

Hey....it is your lucky day.

I just happen to have a broke spoke here at my desk.

The spoke is 5-3/4" (146mm) from the tip of the threads to the start of the bend. You need 18 spokes bent to 80 degrees (88.89 grads), and 18 spokes bent to 95 degrees (105.56 grads). Those spokes are for use with an Excell rim....if you have a different rim the diameter at the spokes could be different.

Title: Re: My trip down RYCA lane
Post by Philmh on 02/12/15 at 17:56:27

George!! Awesome build!!! Your post has finally answered my question! I have been trying to figure out what the solenoid module was. Now I know. I am attempting to remove it from my build as well and unfortunately, my skills in electrical wiring are far worse than my mechanical skills. I can solder wires, but can't read a schematic. You mentioned that in order to remove it, you need to solder the power wire to the rest of the starter system circuit. Which is the power wire in the picture included and where would I solder it to? I am going to assume that I can just cut the remaining wires and leave them in the harness if I so choose?

In the picture, for clarification, the wire colors from left to right are yellow/black, red/white/blue, yellow/green, black/white, and black/red.

Title: Re: My trip down RYCA lane
Post by Gheorghe on 03/31/15 at 11:27:42

sorry I haven't been around in a while, I will let you know which wires you have to hook together when I get home.

Also, bike if for sale. It is on ebay now but PM me if anyone is interested.

Title: Re: My trip down RYCA lane
Post by Violent_Rage on 04/24/15 at 00:27:00

Cool!

Very good job!!! ;)