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Message started by spdfrek on 08/20/14 at 14:29:37

Title: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/20/14 at 14:29:37

Well I have been thinking about this build for a few years now but I always had other projects going on. I finally decided to build it, so here we go.

Day1
Picked up a 2006 S40 with 980miles. Other than needing a new battery and it was dropped on its left side it is in great shape. When it went down it must have been a very slow speed because there are scratches on the rear shock, the end of the handlebars and the rear turn broke. The plan is to order the RYCA kit but I do want to change a few things. I got the factory rear bags too but they aren't on the bike.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-fx2qKBs/0/M/IMG_0529-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-Pp4XSg2/0/M/IMG_0536-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/20/14 at 14:32:57

Day 2
I ordered the RYCA kit and it should be on its way soon. I also went to Harbor Freight and got my new bike jack. I got the bike on it and strapped it down. I pulled the exhaust and windscreen but it was a true "garage nite". There was more sitting around, looking and talking than real work.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-GpWwWN4/0/M/IMG_0653-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/20/14 at 14:36:17

Day 3
I don't have my new parts yet but figured I can get a head start pulling everything off that needs to come off anyway. I am trying to take pictures as I go incase I need to reference them later. I have also been keeping all related hardware with it's corresponding part so there isn't any confusion if I need to go back.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-b33qGzp/0/M/IMG_0659-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/24/14 at 17:46:17

Day 4
I got motivated and pulled everything else off the bike. I even started to cut, grind and touch up the frame where I need to. My new biltwell seat came in too. I hope to have everything ready to go as soon as my parts come in. I have been rethinking a few things but can't make a decision till the kit is here and I get a good look at all the parts.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-rWv5f9z/0/M/IMG_0661-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-LmZnDrn/0/M/IMG_0665-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-V6K3bGf/0/M/IMG_0667-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-2X9FXCp/0/M/IMG_0664-M.jpg

I was told the biltwell seat will not work with the mounting setup that comes with the RYCA kit so I will need to figure that out later too.

Title: Re: Sdpfrek's RYCA Bobber build
Post by Demin on 08/25/14 at 05:50:14

Use a universal mount kit.Bolts right to where gastank/front seat tab bolts to.
http://p1.bikepics.com/2013/11/04/bikepics-2612992-800.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/26/14 at 17:06:37

Got my kit today and just did a quick once over. Looks like the rear frame got a small scratch but not bad for traveling across the US. :D
I am missing two small things but that should be handled easily. I was looking at my frame where I cut the top rear shock mounts off and I thought I was happy with what I did but after another look I think I am going to try to clean it up a bit more. Hopefully I can get some garage time this week and get moving on putting it back together.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/31/14 at 20:57:47

Day 5

I looked at the frame where I cut it and was not happy so trimmed it a bit more. I ground it down then sanded it and finally painted it again. It is still not as clean as I want but it is way better and most people wouldn't see the difference but I do.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-bmGVTkP/0/M/IMG_0668-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-9vkMZh5/0/M/IMG_0669-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/31/14 at 21:02:24

Day 6

This was a supper nonproductive day. All I did was get the tires mounted and checked out the local Suzuki dealer. I should have taken pictured with the new tires but didn't. Either way you can se them in the next few pictures.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/31/14 at 21:09:49

Day 7

Ok, now I am starting to make some real progress. It is starting to look like a bike again. I lowered the forks and got them back on. Getting that top cap back on was seriously energy draining but I got them on. I got the front wheel and brake caliper back on too. Then I drilled out my new pegs and put those on. I got the new hardtail mounted. That took a bit too since it is super tight. I put the back wheel on just to see what it looks like. I also put the tank/seat bracket on the backbone but didn't secure it. It was a hot day and I was pooped. Oh yah, I also got that stupid coil mounted. The kit said to just bolt it on but it didn't go that well. To begin the holes on the frame were way too close to each other compared to the holes n the coil. Plus drilling out the coil was a pain since you are drilling through stacked sheet metal and not something solid. Like an idiot I stripped the rear mounting point and thought I could just put a nut and a threw bolt on instead. I did get it to go on but it is so tight I had to use needle nose vice grips to even hold the nut inplace while I tightened the bolt. But it is on.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-Tt3Kfqd/0/M/IMG_0675-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 08/31/14 at 21:18:17

Day 8

It was pretty hot today too so I wasn't out in the garage till later and didn't get as much done as I wanted. I did get the backbone bracket on so I was able to mock up the tank. I was told the Biltwell seat I have will not work with the RYCA kit so I had to come up with a way to make it work. I don't know if it was the heat or my brain that just wasn't working but I kept thinking up ways that were way too complicated. What I ended up doing was flipping the seat springs around backwards and bending their mounting points quite a bit. I had to bend the part that mounts to the frame so that the spring didn't contact the frame and the top mounting point so it lined up with my seat pan better. I cut and drilled a pice of flat stock so I can bolt the springs to it and then bolt the seat to the plate.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-LRGsmnd/0/M/IMG_0679-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-fT2gcjt/0/M/IMG_0680-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-3tRPhZZ/0/M/IMG_0681-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-wMJ5k6w/0/M/IMG_0678-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by NickGann on 09/01/14 at 05:06:07

This is a thing of beauty dude

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/01/14 at 09:26:18

43444E464A4C43432D0 wrote:

This is a thing of beauty dude

Thank you. I am still trying to decide paint. I have two different designs in mind and each one has a different exhaust and rear fender so I need to call the paint guy to get a ballpark idea what its going to run me so I can decide what direction to go in.

I went out to put a coat of paint on that flat stock and decided to look at the seat again and I don't know what I was looking at last night. There is no way this will bolt on. I need to either make a new wider plate or borrow my friends welder and weld some tabs onto the plate I have to even think about it working. I am not counting today as a work day because I just don't want to even look at it now. ;D

Title: Re: Sdpfrek's RYCA Bobber build
Post by Jeff71 on 09/01/14 at 09:56:30

If you need to sell the stock tank, let me know. ;)
Jeff

Title: Re: Sdpfrek's RYCA Bobber build
Post by Demin on 09/01/14 at 13:00:23

Looking good !!!!!! 8-)

Title: Re: Sdpfrek's RYCA Bobber build
Post by strang on 09/02/14 at 01:34:05

dig the whitewall tyres. I mean aqua : )
looks cool dude.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/02/14 at 19:26:06

Yah I figured I would wash the wheels once I was done so I don't mess up the white walls during the mock up.

Day 9

I got the seat brackets figured out. They might not be pretty but they work and when the paint dries you won't be able to see them.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-Jwkjhc4/0/M/IMG_0683-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-rLJxddB/0/M/IMG_0684-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/06/14 at 23:13:02

Day 10

I started out the day thinking I was going to tackle the wiring. I wanted to cut out all the extra stuff that I was taking off the bike to just clean it up a bit. I have a Clymer manual and was looking at the wiring details that are in there. There are wiring schematics for 1986-2003, 2004, 2005-present. My bike is a 2006 so I figured it should match the 2005-present but it is actually closer to the 1986-2003. I am not sure what that is all about. Either way I didn't get very far and decided to get my chain and tensioner put on instead. I also did not like the open frame tubes from where I cut the frame so I got some nylon caps and sealed them up.

Started with this
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-F8LHBjm/0/M/IMG_0686-M.jpg

stopped at this
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-7XtXRGr/0/M/IMG_0687-M.jpg

Then got this done
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-CX3FBg4/0/M/IMG_0689-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-thwK5bm/0/M/IMG_0691-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by scrapdo on 09/09/14 at 17:04:51

I'm about 75% done with my Ryca Bobber buil too. I'll have to post about my issues!
Nice work so far

Title: Re: Sdpfrek's RYCA Bobber build
Post by scrapdo on 09/09/14 at 17:05:31

7D7E6A687C6B650E0 wrote:

The mounting points on mine were fine but drilling the coil went VERY bad. The metal is mangled quite a bit on several layers. Does anyone know if this causes a problem starting? I have the wiring finished and just wanted to text the spark and I'm not getting one. I turn the key and hear a click but when I try the starter, nothing!

I thought I might have ruined the coil while drilling??? Any suggestions??

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/12/14 at 13:59:09

4757465544505B340 wrote:

I messed up the last layer on the coil when I was drilling mine out too but found if you give it more speed it doesn't catch and tear it up as bad. As far as your not starting issue did you bypass the clutch switch?

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/12/14 at 14:02:02

Day 11

I looked at the wiring again and did a better job of tagging what I am keeping and what I am not. The more I look at it I think I am going to just cut out what I need and rewire everything to make it easier.

I didn't take any pictures since nothing really changed other than more masking tape on the rats nest of wire.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/12/14 at 14:13:49

Day 12

I decided to change my handlebar setup and mocked it up with 2.5" spacers. I am also going to get rid of all the factory controls on the bars except the brake and clutch.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-jMr68jP/0/M/IMG_0692-M.jpg

I also got my new tail light and brake pads in so put the pads in and made an extension to be able to use this light with my license plate bracket.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-TMPVCgR/0/M/IMG_0693-M.jpg

This,
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-jgwph8S/0/M/IMG_0696-M.jpg

will go on here to mount the light.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-DsgSz9C/0/M/IMG_0697-M.jpg

I also started looking at making a bracket for the left side to mount my speedometer and starter button. I made the cardboard template and realized the gauge needs to be about 5" forward or will be right where my leg needs to be. ::)
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-98V9LNh/0/M/IMG_0695-M.jpg
This is real ruff, just to get an idea of where things will fit but I didn't want to keep it as big as I originally made it. In the end it doesn't matter since I will be redoing it again, probably tonight. Even with it moved forward I think the stock cable will reach it so that is good. I also am thinking I want to sink the gauge into the bracket so it doesn't just sit onto of it. I need to look at how to get that to work.

Title: Re: Sdpfrek's RYCA Bobber build
Post by Dave on 09/12/14 at 17:46:04

And I felt that taking my eyes off the road long enough to glance down at the tank to read my speedo was dangerous....I can't imagine having to look down at the left side of the engine!

I suppose you don't really have to look at the speedo all that often.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/12/14 at 22:18:54

62595443525E454358505D42310 wrote:

The new template has it set more forward. It is closer inline with where the stock gauge used to be but lower to the ground. You can easily glance down and see it plus its not like you watch it. It is more of a "am I going too fast for this road" check.

Think of it like this, while driving a car have you ever looked at your radio to check the time? Yes you take your eyes off the road but its not like you are trying to read the paper on your lap while driving to work.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/12/14 at 22:28:12

Day 13

I didn't get much done tonight because it was just too cold. I got the tail light on to see what it looks like and made a template for the new bracket for the speedometer. I want to get it cut out tomorrow and see how it really fits.

The light looks crooked here. I guess I better look at that tomorrow too.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-5HCQ4gt/0/M/IMG_0698-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-TfzzN3h/0/M/IMG_0699-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by NickGann on 09/13/14 at 19:22:52

That is a smooth ass bike man

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/14/14 at 18:36:14

2C2B212925232C2C420 wrote:

That is a smooth ass bike man

Thank you.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 09/14/14 at 18:51:48

Day 14

I made the speedometer bracket. This thing took a lot longer than I thought it would but I put it on the bike and off about 5000 times. I am pretty happy with how it turned out. It is stable and gives me room around my leg plus the stock cable fits too. I did make a sleeve to go over the front bolt because I didn't want to see the threads. I also made a support leg like the stock engine cover and even used the rubber foot. I didn't paint it yet because I still need to drill and mount the starter button and I am thinking I can put a small neutral indicator light on it too.

I did take a few more pictures with this since its more of a custom piece.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-nHWNzVw/0/M/IMG_0706-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-64cNdgH/0/M/IMG_0709-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-zXptFcF/0/M/IMG_0710-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-Dk5WdKN/0/M/IMG_0711-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-fk3XgR3/0/M/IMG_0712-M.jpg

If anyone is wondering the front sleeve is just some brass tubing I had around the garage and the smaller "support" leg is some automotive brake line that I cut.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 11/23/14 at 15:26:09

I haven't been updating this and really haven't been spending very much time working on the bike. Life got in the way so I only got a few min here and there to try to do something but I am still moving forward.

Days 15-18

I spent a few days going back and forth on the wire. I have everything done except for the positive to the battery because I am looking for something like the factory connection that has those small wings on the sides instead of just a plain ring terminal. I have the wire done but I already want to redo it because I don't like how I ran them.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-mDfLSFr/0/M/IMG_0746-M.jpg

I also got my new spacers made and installed.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-chgZBzJ/0/M/IMG_0722-M.jpg

I also made a battery tie down.
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-LHWj9d7/0/M/IMG_0767-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-DCzmD7D/0/M/IMG_0769-M.jpg

The cut out in the center is for the built in tester.

Title: Re: Sdpfrek's RYCA Bobber build
Post by TC on 11/24/14 at 13:04:12

Great thread man! So far it's my favorite bobber build to date. And my eyes don't hurt from trying to decipher your posts. Thanks for that [smiley=thumbsup.gif]

Title: Re: Sdpfrek's RYCA Bobber build
Post by Art Webb on 11/24/14 at 19:53:42

So THAT"S where one relocates the battery onto the swingarm, lol

Title: Re: Sdpfrek's RYCA Bobber build
Post by paulmarshall on 11/24/14 at 20:47:20

Its a lovely looking project, well done.
Just a question does the seat sit center to the rear wheel? One of your photos looks like the seat sits to one side of the wheel.

Title: Re: Sdpfrek's RYCA Bobber build
Post by Demin on 11/25/14 at 08:28:13

VERY KOOOOOOL 8-) 8-)

I was thinking the same thing.

Title: Re: Sdpfrek's RYCA Bobber build
Post by spdfrek on 12/04/14 at 16:55:32

The seat is centered it just looks off in that picture plus it is not bolted down yet either.

Day 19

I finished tucking the wire into its new home and ordered the rear fender. I also called the guy painting this thing so I am waiting to hear back from him. I don't remember when but at some point I did swap out the headlight and I wired the blue high beam indicator to act as my neutral light.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-z8K5NKW/0/M/IMG_0777-M.jpg

Here is the finished speedometer plate. The silver button next to the decomp lever is the start button and the rubber button is for my high beam.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-krk4SQ9/0/M/IMG_0775-M.jpg

It is getting closer to being done.

http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-Ttpz32L/0/M/IMG_0773-M.jpg
http://spdfrek.smugmug.com/Motorcycles/2006-Suzuki-S40/i-xJqmMSx/0/M/IMG_0774-M.jpg

Title: Re: Sdpfrek's RYCA Bobber build
Post by TC on 12/06/14 at 14:34:48

Dude. Looking forward to seeing how you finish it out! So clean though.

Title: Re: Sdpfrek's RYCA Bobber build
Post by DJGCWB on 12/18/14 at 07:34:06

Very nice build!

I was told that there are no white wall tires that will fit on my Savage... Did you have to do anything special to get a different size front tire so that you could get white wall?

Title: Re: Sdpfrek's RYCA Bobber build
Post by Art Webb on 12/19/14 at 09:42:49

modifgied / deleted front fender I'd guess