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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> 1987 Savage Street Tracker build /cgi-bin/YaBB.pl?num=1632771935 Message started by TheSneeze on 09/27/21 at 12:45:35 |
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Title: 1987 Savage Street Tracker build Post by TheSneeze on 09/27/21 at 12:45:35 I have finally pulled this bike out of a corner in my shop and got it up on the stand. I bought this bike in early 2019 for some suspension parts I wanted for another project. With that project finally nearing completion, the time came for this one to get some love. This is how it is right before it went on the lift. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 09/27/21 at 12:50:47 On the lift |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 09/27/21 at 12:51:59 Going down to the frame. Ready to start pulling the motor out. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 09/27/21 at 13:47:26 You should be thinking about this... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1288911670 |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 09/27/21 at 13:59:34 Thanks! Just added this mod to the list. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 09/27/21 at 17:45:16 Now you know you have to check the teeth on your starter gears. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 09/27/21 at 17:57:49 This motor is an unknown. It turns over (not with the starter), and has some compression. I haven't measured the compression yet. Still on the fence between trying to see if the motor will start and tearing it down for a rebuild. I am leaning 70/30 toward the engine tear down. I just finished a frame off resto-mod on a 1981 Kawasaki KZ750e2 that included a motor rebuild. You would think by now I would know better with old bikes! Hahaha! Not all of the wiring is present on this Savage. I will be rebuilding the electrical on this as well. |
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Title: Re: 1986 Savage Street Tracker build Post by justin_o_guy2 on 09/28/21 at 08:32:36 Keep the cylinder happy. A bit of oil is a good thing. If that pressure washer craps out ,if it's like mine was, it has a very serious, tubular magnet in it. I can pick up a ten pound sledge hammer with it. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 09/29/21 at 17:52:31 I finally started to order parts for this build. Usual stuff like gaskets, seals, filters, etc. I called up Airtech and ordered the new seat fiberglass. It's going to be fun figuring out how I want to mount it. I decided to go with 18" rims front and back, stock widths of 2.15 front, 2.75 back. Buchanon's will be doing the wheels for me. Thought about lacing them myself, but decided for a professional assy and true. I'm considering some Avon dual sport tires to finish off the wheels. The rear will be close on the swing arm, but I can cut and weld for any additional room needed. The belt drive will be replaced with a 530 chain and sprocket setup. A ton of good information on this site! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/01/21 at 18:03:10 I ordered the tires today. I chose the Avon AV53 / AV54 Trailrider Tires. 110/80-18 for the front, and 120/80-18 for the rear. I want to get the hubs shipped off soon as every part of this build needs to start with the correct ride height and wheels. The bike will be down to frame this weekend. While the wheels are being built I will get the forks apart for new seals and dust boots. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/02/21 at 15:14:20 Just the motor left to pull. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/03/21 at 16:29:49 Off to Buchanon's this week for new rims, spokes, and nipples. |
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Title: Re: 1986 Savage Street Tracker build Post by Armen on 10/04/21 at 08:52:03 Nice! Two hints: Maybe go with a 520 chain? Plenty strong. Lighter. Make sure the rims Buchanans use are 'safety' rims so you can do the Outex tubeless conversion. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/04/21 at 14:46:02 The new tires showed up today. The rear is getting taller, and the front is getting a little shorter. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/04/21 at 14:46:44 this is the rear |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/04/21 at 14:47:54 Of course I had to put them up to the frame just to see how it will look! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/04/21 at 14:48:23 From the rear |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 10/04/21 at 17:14:59 That's a serious lookin tire. I like it. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/06/21 at 15:57:16 I ordered the seat/tail section from AirTech. I chose the #DTS6 because the dimensions fit the closest with the LS650 frame. They make their products to order, so this item is about 4 weeks out. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/09/21 at 18:59:27 I have been busy ordering a lot of seals, gaskets, bearings, and such. I ordered some rear shocks from CL Moto Tech's website, but he posted a message that his shock business was being shut down for the summer for various reasons. The website still allowed the online store to take an order though. I am not in any rush on this build, so hopefully he will sell me a set. The forks are on the bench. Those are coming apart while Buchanon's does the wheels. Swing arm bearings and seals are on the way - swing arm was really stiff! This bike has been sitting for a while. I need to put my borescope into the tank and see if it needs any love. Petcock change is in the plan. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 10/10/21 at 06:32:46 I love a good build thread!! Personally, I would never build a bike until I know that's it's a runner, but you seem to have the confidence and experience to pull it off. Most people would be wise to get the bike running properly in before proceeding. If they can't do that then they would be better off finding another bike to start with. These bikes are relatively cheap and easy to find. We have seen others come on here attempting similar builds only to fail and disappear. One guy even took a perfectly good S40 and modified it the engine, carbs, electrics, etc. He ended up with a cafe bike that he couldn't get to run correctly when he was done. He came close and then disappeared. :( |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/10/21 at 10:03:13 I just finished a 2-1/2 year resto-mod on a '81 Kawasaki KZ750 that sat outside for 28 years. This bike doesn't scare me! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/10/21 at 10:04:18 Here is where it sat when I picked it up. It was in rough shape! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/10/21 at 10:08:41 Worst case scenario is the motor comes apart for a full rebuild. After an inline four this single cylinder should be a piece of cake. I became a certified motorcycle mechanic back in 1976. I ran a metal fab shop for 24 years before I retired. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/10/21 at 10:47:35 Outstanding job on that Kawasaki |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/10/21 at 10:55:51 Thanks! I love your cafe Savage! I have read an awful lot of your posts on suspension and modifications. A ton of good info... |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/10/21 at 11:21:19 Here is my street tracker build |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/10/21 at 19:30:24 Very nice! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/11/21 at 11:44:13 I have been seeing some pretty crazy prices for a lower triple clamp as most are being sold with the upper and stem. All were going for $50-$100 on Ebay. I kept patient, and waited for a better deal to come up. Just scored a lower triple clamp with stem, shipped for $22. It is relatively good condition, better than most in the full sets. I'm happy! ;D |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/11/21 at 12:10:22 Yep. It's more important to get a cheap one than a nice one. Get an ugly one, you are going to be polishing/blasting it anyway once the turning stops are removed. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/11/21 at 15:16:24 I'm having a forking good time today! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/14/21 at 07:13:02 As I wait for more parts to arrive, I got a 12" square sheet of 5/16" thick Buna-N rubber and cut out my own gas cap gasket. I wasn't real thrilled with the idea of using a "lavatory gasket" as others have. I went with a medium soft durometer material to get a good squish when closed. Today I am going to have a look inside the tank with my borescope and find out the condition inside the tank. The exterior is very scratched up, and the clear coat is peeling off in large areas. The plan is to seal off the openings and put it in my blast cabinet. Going to take it down to bare metal. Another part on the way is a new petcock for a Razor 650, genuine Yamaha part (new). The speedo looks pretty easily removed, so no worries there. I am not sure if I will use the OG side covers or make my own. That will be determined after the seat/tail arrives and I can se how it looks on the bike. Buchanon's should be shipping my wheels soon. I expect to see them early next week. I doubt I will have the swingarm bearings replaced by then as I am still waiting for a shipment confirmation. Tomorrow I will get the lower triple clamp I ordered off of Ebay. Fork seals should be coming with the swingarm bearings. Maybe this thing will turn into a roller by the end of next week. I am still doing a lot of research on converting the foot controls to mid or rear mounts. One of the things I did with my Kawasaki build was adding frame gussets. Has anyone seen any info on whether or not that would help on a Savage? Not sure if the bike is heavy enough to warrant it. I am still trying to decide if the frame will be refinished, or left as is. There are a lot of scratches from the tank being removed (many times!) and the stock petcock being dragged across the frame rail. I haven't found any rust to speak of. If I don't do any welding on the frame, I am leaning toward leaving it as is. The seat/tail section mounting design may involve some welding - it would be nice if I can design the mounting as bolt on to avoid refinishing the frame. Time will tell! |
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Title: Re: 1986 Savage Street Tracker build Post by Tocsik on 10/14/21 at 14:09:22 I'm enjoying watching this so far. My bike came with the same petcock scratches on the frame, and some back by the seat mount points, too. :( |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/14/21 at 15:28:40 This is the used lower triple clamp I picked up. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/14/21 at 19:37:13 That’ll clean up nice. Press out the stem and use a unibit in a vice to open it up to 7/8”. Knock off this steering stops and shine it up. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/14/21 at 21:15:38 The ID is already bigger than what needs to fit on the top of the steering stem. I think I need to have a sleeve pressed into it so it fits the stem. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/15/21 at 08:00:04 I went back and checked my build thread. The stem is your spacer. Cut it down to 25mm and press it back into the t-clamp |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/15/21 at 08:31:31 747E7A707B72767F212723130 wrote:
I went back over your thread yesterday and must have missed that tidbit of info. That makes more sense than what I was thinking - have a press fit aluminum spacer made, then drill to size after pressing. Thanks again, Gary! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/15/21 at 11:52:20 I just checked in with Buchanon's on the status of my wheels. Apparently they shipped UPS GND two days ago. Really looking forward to seeing them arrive!! 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/15/21 at 12:40:44 And less than an hour after checking they showed up on my door step! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/15/21 at 12:41:57 The new rear. As stated earlier in this thread, both are now 18". Front is 2.15" and rear is 2.75. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 12:52:00 Since I didn't want to booger up these new rims, I took the wheels to the local motorcycle shop to have them mounted. While that is being taken care of, I took the swingarm off to put new bearings in. The swingarm was really stiff to move which is not surprising since it is unknown how long it has been since it was ridden last. The right side was still greased and operating smoothly. The left side, well... not so much! This is the lower side when sitting on the kick stand, so any moisture would accumulate here. This is the worst bearing I have ever pulled apart! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 12:52:27 top side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 12:59:17 I put my borescope in the fuel tank. I found the expected mild rust here and there. The nice part is the tank had been drained, so there weren't any areas of grunge or varnish. I will soak the inside with my usual go-to, Evap-O-Rust. This stuff works really good. My new petcock showed up the other day. OEM Yamaha Raptor unit. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 13:06:41 The fuel tank is fully disassembled and ready for stripping, inside and out. There are a few small dents, but overall is it a sound tank. Not near as bad as the last tank I dealt with! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 13:07:05 bottom view |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 13:09:15 Earlier I mentioned I was sitting on the fence on whether or not I would take the engine apart or try and get it running as is (with a few new seals and gaskets). This morning I found my definitive answer... someone went after the cylinder with some JB Weld. Well, crap. Looks like this will be a tear down after all. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 13:09:39 another view |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 13:35:55 Looks like someone over torqued the nut on the bottom of the cylinder head stud and cracked that area. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 15:40:14 After removing all of the JB Weld from the area it is more clear what the issue is. Honestly, to me it looks like surface cracks in the aluminum casting surface. But someone wouldn't put JB Weld down unless there was a leak. I am still looking at pictures and sketches (shop manual, peoples pics they have posted, etc.) to see where oil could come from. Seems to me this area is covered on the inside by the steel cylinder sleeve. On this parts diagram, item #26 is a "gasket" that goes under the cylinder head nut under the head/cam cover. If this gasket was leaking the oil would go down the stud and potentially leak over that area. Could this be an incorrect attempt to fix that gasket leaking thinking it was those "cracks" in the surface of the cylinder casting? Or just the head cap seal and not the gasket #26 under the cylinder head nut? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 15:41:40 JB gone |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 10/16/21 at 16:20:06 I believe are just die marks, they are all over all of the castings. The head bolts some times leak oil when the head gasket gets loose. Could be the reason for the JB. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/16/21 at 18:38:55 A leak down compression test is the correct action before decisions are made. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 19:39:37 I agree. I should have a test kit on Monday. But then that same day is my wife's birthday. I wonder what the look on her face will be when she gets a leak down tester for her birthday? :o |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/16/21 at 19:44:58 Let her use it first...you’ll both be happy. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 19:49:29 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 20:31:46 Now that the lower clamp fits the top of the stem I can move on to cosmetics. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 10/16/21 at 21:09:12 2C262228232A2E27797F7B4B0 wrote:
If she uses it 1st, he'll need to consult a proctologist before his turn. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/16/21 at 21:24:56 362532332C2127252E71400 wrote:
If she uses it 1st, he'll need to consult a proctologist before his turn.[/quote] :o :o :o |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/19/21 at 15:32:19 The leak down compression tester arrived. I had to use a breaker bar to loosen the spark plug. Once it let go, it threaded out fine. But I had to lean on it way to hard for a spark plug! Now I am just waiting for the compressor to fill up. (drum roll....) :-/ |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/19/21 at 16:11:45 At 30 psi I am losing 60% of the pressure. It is coming mostly from the exhaust valve. There may be a slight loss on the intake side as well. So at the very least the head will come off for a rebuild. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/19/21 at 17:13:33 Leaking like a sieve. I usually use a reference pressure of 80psi…but if it’s leaking that bad at 30…more isn’t gonna help. Rebuilding a the head is a good opportunity to port the exhaust side and get a more aggressive cam profile and a HC piston. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/19/21 at 22:22:49 Being that this motor is a total unknown, I will wait until it starts to come apart before I start considering what will get altered. If the insides are as bad as I am finding, replacement parts other than stock will be considered. The seat/tail section is shipping any day now. The foot controls and seating fabrication may slow the motor progress a bit. Still hoping to complete this project by spring of '22, but a lot will depend on how quickly I can get parts and materials. Already have a color scheme in mind, but that is way down the line. I should have the wheels back in the next day or two. Rear shocks - I have no idea when. No communication with the seller since I ordered them. He accepted my payment, so hopefully he is a stand up guy. I am going to focus on the front forks and get the swingarm back on so I can plan out the ride height before the motor comes out. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/20/21 at 15:21:15 I finished putting the front forks back together, minus the oil. The stock caps are on only to keep dust out of them until the new fork caps arrive. Once I have those, I will put new oil in and seal them up. I have been looking at handlebars and clamps trying to decide what I will use. I bought fork caps with adjusters, so I really need to wait until they are on to take some accurate measurements and determine how tall of a rise I will need. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 10/20/21 at 23:05:23 I'm lovin the restoration you did on that KZ. Simply beautiful. That thing was in sad shape. You did a great job. My compliments. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/21/21 at 07:31:06 5F59562A282F2B1B0 wrote:
Thank you! It only has a couple thermal cycles on it, not even broken in yet. I was trying to get 500 miles on it before the weather turned too cold, but we had our first snow a month early this year. :'( I went with 10.5:1 compression pistons on it since it had to bored .030" over. Can't wait to see how it handles in the twisties! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/21/21 at 09:04:26 So I have decided the frame and swingarm are going to be powder coated. I am going to change it from the stock black to metallic silver. This brings up an issue with the VIN sticker - it will be destroyed blasting the frame clean. I had a friend in So Ca that had a high quality decal business, so when I did this to my KZ, he duplicated the VIN sticker for me (it was all white with black text). The Savage VIN sticker is a bit more complicated, though. Also, I lost my friend to COVID last December, and the decal resource along with it. Does anyone know of a quality company/person who could replicate the VIN decal? This one is a foil sticker, with a black background, white lettering, and some silver areas with a stamped character. I don't need it to be foil, but all the colors should be present to mimic the stock appearance. Any recommendations would be appreciated! |
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Title: Re: 1986 Savage Street Tracker build Post by Ruttly on 10/21/21 at 11:31:16 The frame is also stamped , well mine is ! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/21/21 at 12:10:58 4F68696971641D0 wrote:
I am aware of that. I still want to replicate the sticker. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/21/21 at 12:45:28 Can the existing identification plate be removed with heat? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/21/21 at 14:33:02 It's old and busted. It looks there may be a character rubbed off immediately following the NP41, just before the silver background starts. I grayed out the serial number because, well, the internet!! With a nice coated frame I want the VIN plate looking just as clean. May seem silly to some, but I have my quirks! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/21/21 at 14:42:54 By deciphering the VIN code on this site (wonderful resource, this place!), I have discovered my bike is actually a '87 made in Nov. '86. It is an H, not a G. Well, what do you know... I have the last two bill of sales and they both list '86. Also, there is a numeral 1 rubbed off between the NP41 and the 3. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 13:16:22 There is something about parts showing up at your door during a bike build that really puts a smile to my face! I finally got the wheels back with the tires mounted and balanced. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 13:19:01 Then my seat/tail section arrived from AirTech! Now that these major pieces are present, who could resist just mocking them up in place? Not this guy!! This is just setting the seat in place (sort of). |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 13:21:20 Okay, that's just not going to wet my whistle... I need the wheels in place and the tank on to see where the seat REALLY sits! So this is with everything (very loosely) in place. Now I can get a real good visual on where this is going. And I have to say I AM LIKING IT!!!!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 14:54:07 Going with an 18" rear rim and a 120/80-18 tire was a bit of a crap shoot on how it would fit with the swingarm. I knew it would be close. To make full range of the chain tensioning slots in the swingarm, it will require some cutting and welding. It looks like I need about 3/8"-1/2" more clearance to avoid tire rub at the fully tight position. After the sprockets and chain are on and I can see where the chain will be cut I will take some final measurements before actually cutting anything. With that bit of knowledge, and seeing how the seat/tail fits, both the swingarm and frame with see some welding. And that means both will get totally stripped and powder coated. Color change will see them metallic silver, and the body work will be Navy blue. 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/22/21 at 15:06:29 It does look good. It’s a shame that the swingarm can’t maintain that angle. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 15:20:20 Yeah, this is not the finished ride height at all. Just a very loose mock up for visuals. The rims, spokes, nipples, and assembly at Buchanon's wasn't cheap by any means, but the end result is worth it! They do really amazing work. All parts made at their own manufacturing plant. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 15:40:39 So this is pretty close to what the angle would be at full shock extension, so actual ride ride will sit a bit lower. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 15:58:23 Well, Gary, you got me going. After moving the board stack around, and measuring the rear shock mounts, then doing it again... thanks to my wife for adding and deleting boards while I lifted! This is about where it will sit under rider weight to my best guess at this point. This is reflecting about a 1/2" compression on the shock from full extension. Until I have the shocks I don't think I could get any more accurate than this. Definitely looks more realistic in this stance. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 16:31:53 angle #1 |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 16:32:17 Angle #2 |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/22/21 at 18:27:33 You will find with the OEM swingarm, the longest shocks the bike will tolerate without chain slap is 13.25”. At just 1/8” longer the chain will contact the heading edge of the swingarm when the suspension unloads. Just as well, the steering trail will be a short 3.25 inches with the wheel and fork set up you have there. BTW, I have used Buchanan spoke kits too with Sun rims. The spoke kits are spot on. I’ve never had them build them because 1) it was fun to learn (and it’s easy) and 2) I’m too darn cheap. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 18:53:42 CL MotoTech offers either 320mm (12.59") , 340mm (13.38") , or 360mm (14.17") . I figured 320mm was too short. 340mm too long? I have seen some builds with a abrasion resistant material wrapped around the front of the swingarm for protection like most dirt bikes. An option if needed. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/22/21 at 19:24:55 The CL Moto shocks are adjustable and are available in 310-320mm or 330-340mm. The chain guide material is just that, a guide. When the chain rubs it will become a sacrificial material and will wear quickly. |
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Title: Re: 1986 Savage Street Tracker build Post by SpamyToo on 10/22/21 at 21:43:10 4A5570777D74786B72190 wrote:
Looks like a bottom triple on the top. Just wanted to point out that you can get a nice new top clamp if you wanted to. dcmotive.com/products/suzuki-ls650-s40-savage-flat-pinch-triple-clamp |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/22/21 at 22:34:05 Once I saw the cost of some of these upper triple clamps, I went with modifying a stock lower. I paid $22 plus shipping and some labor. The budget is not limitless. Money saved in areas like this means more available to spend where it counts. Just my $0.02... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/23/21 at 14:50:54 I have never seen a zinc plated steel spark plug adapter used in an aluminum motorcycle head before. This adapter does not show on the exploded view of the cylinder head on Partzilla. The spark plug was way too tight, and hard to break free taking it out. It is the correct plug - NGK DPR8EA 9. Is this an aftermarket adapter or stock? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/23/21 at 14:55:53 I have 1/4" of slot left in the chain tensioner when my tire is against the inside of the swing arm. I'm planning on removing 1/2" for clearance. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/23/21 at 14:56:39 contact |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/23/21 at 15:09:05 Bad news on the spark plug, it looks like someone tried to make a repair with an insert. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/23/21 at 16:37:56 It didn't look stock at all to me, not that I have ever looked at a LS650 head before. Just didn't seem right. I will evaluate the head closer when it comes out. After the leak down test, I already planned on a head rebuild anyway. Now it may be rebuilding a good core head. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 10/23/21 at 17:20:44 looks like an old oil burner adapter. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/27/21 at 14:29:55 I picked up some metal stock to start the seat/tail mount. After much head scratching, beer, some more head scratching, some more beer, I figured it would better to have some other components in hand before going crazy on it. Like the tail lights and turn signals. And license plate holder. I stumbled across this unit on Amazon, and there are several reasons I like it. It will tuck under the tail well, it already has turn signals incorporated into them, and I won't have to make a license plate holder. The holder it has is also angled giving some additional assurance the tire won't come into contact under full compression. There are more bits I need before I start the seat mount that are their way as well - the stock rubber bits that mount the rear of the tank. I plan on tying the front of the fiberglass seat into the rear tank mounts. I believe I can pull off the mounting frame without any cutting or welding on the frame and have it completely bolt on. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/27/21 at 14:37:30 While the tracker rear fairing you are using has a different shape than my cafe hump, it looks about the same on the bottom - flat. My license plate got bent about 3 or 4 times before I removed it and mounted is as an "inner fender". I think you will have to remove the license plate bracket from the light assembly. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/27/21 at 14:48:43 4B41454F444D49401E181C2C0 wrote:
I removed the part from the spark plug hole, and then immediately felt like an idiot. That piece is the leak down tester adapter! When I removed the flex hose, it unscrewed from the adapter instead of coming out as a complete assembly. D'oh!! :-[ The spark plug threads look fine. Good news is the head is more than likely rebuildable. Bad news is, it doesn't change the result of the leak down test. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/27/21 at 14:51:35 My tail section sweeps upward a little more than yours. When I receive the tail light assembly I will see how it tucks under, and how far down the plate would hang. Another reason why it's better to have all the components present prior to starting fabrication on the mount frame. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/27/21 at 14:59:16 I will test the range of travel on the rear suspension when the assembly arrives, but you can see this tail section has more rise than your cafe hump. (what hump?!) |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/27/21 at 15:50:17 Yeah, you have a lot more room. If you are going with a chain drive and 13.25”’shocks, you’ll have about 4.25 of wheel travel. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/27/21 at 17:10:26 Where it sits right now, there will be 8-1/2" from the top of the rear tire to the bottom of the tail when I am done with the mount. Once the tail light assembly is here I will be more certain where it will all end up. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/27/21 at 17:51:38 So if you have 8-1/2" of space, that the wheel can move up 4-1/4", that leaves you with 4-1/4 of room for the light/plate assembly (with plate). You should be fine. Oh, I went and checked my notes, the longest shock you can use is 13". At 13.125" there is contact. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/27/21 at 18:13:30 I was looking at how close the chain will come today, and realized some of the chain guard mount brackets will have to be removed. Not that I have a chain guard with this bike. It is missing quite a few details. In the next 4 or 5 days I should see the handlebars, fork caps, tail light assy, rear tank mount pieces, and a bunch of gaskets and o-rings for the engine. Brake caliper and master rebuild stuff is on its way as well. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/28/21 at 16:40:58 I started to work on some of the seat/tail mount today. I am using 3/8" diameter steel round bar for the support of the tail section. A little tricky hand forming this with just a vise. The fact that the fiberglass is not symmetrical didn't help matters. The ends are a left a little long for trimming. I am using some 5/16" thick rubber between the fiberglass and the steel plate that will bolt to the existing seat frame mounting points. I will have a cross brace of some sort directly under the seat where the largest amount of weight from the rider will be. This is all very preliminary and the final design is still in a state of flux. I will design the tail light mount off of this piece. |
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Title: Re: 1986 Savage Street Tracker build Post by badwolf on 10/28/21 at 17:08:51 Tubeing is stronger than solid round bar,& lighter too. Try to find some steel 1/2'' tubeing (not conduit), and borrow a electricans bender. A little heat and you can bend it pretty easy, and you will end up with a better product. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 11:20:35 I hear what you are saying, Badwolf. But there are some drawbacks to using thin wall tubing. It can be more difficult to weld (I don't have TIG welding ability, only MIG), collapses easily without the right tooling (I don't know any electricians), and my access to materials is limited as I live in the country. Not trying to make excuses, but there was thought put into my material choice. The nearest raw material supplier is 50 miles away from me. I was able to get the material I am using at the local hardware store. Weight isn't a big concern for me as this bike will still be lighter than the stock version, by a substantial amount. The mounting points at the frame will carry the majority of the load. It's not like someone will try to sit on the tail section or carry a passenger. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 14:07:48 The plate in this picture bolts directly to the seat/fender mount "horns" on the frame. These two hoops will be joined by two straight pieces. I need to wait for the stock bits for mounting the rear of the fuel tank before I can build the front of the mounting frame. The front of the seat and frame will tie into the rear tank mounts. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 14:10:46 I got my tail light in the mail today. It wasn't clear how big or small it was in the ad, so I am pleasantly surprised that it fits the size of the tail so well. It is 5" tall including the license plate bracket - I may need to increase the bend angle on it to clear any interference with the tire. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 14:11:25 angle view |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 14:17:14 You really have to be wary buying parts off of Flea-bay. The clutch lever holder was broken on this bike. I found a couple replacements on that site, but almost all were questionable cosmetically. I finally found one that was really clean except the lever was bent. The lever that came with my bike is straight and clean, so that wasn't a concern. The part arrived today and what was shipped was severely yellowed, and clearly was not the part pictured in the ad. Needless to say I left a negative review on the seller, and sent them a message voicing my displeasure. I am going to try and clean it up, but misrepresenting the part you are going to ship is BS!!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 14:30:16 more bits |
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Title: Re: 1986 Savage Street Tracker build Post by badwolf on 10/29/21 at 14:33:02 Your tailight looks like a pair of goggles from ''Mad Max'' Cool! |
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Title: Re: 1986 Savage Street Tracker build Post by Armen on 10/29/21 at 15:15:26 Not to hijack the thread, but... Badwolf said: "Tubeing is stronger than solid round bar,& lighter too" Absolutely not true. Tubing is stronger than solid of the same weight, because the solid would be much smaller OD. In the same OD, solid is always stronger. The air inside a tube isn't stronger than solid steel. The strength of tubing increases as does the square of it's diameter. So, given the same weight, you can get some seriously huge diameter tubing that is stronger than the same weight of small OD solid. Common misconception. But, air is not stronger than steel. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 10/29/21 at 15:46:21 I was going to say that, but was looking for a cooler way to say it so it stuck. Like... Pound for pound, it's true a 2" dia tube can be a lot stronger than a 1/2" bar and weigh the same. But a 1/2" tube versus a 1/2" bar, no way. You remember the cargo door fiasco in the 90's? I had a hand in fixing that. Turns out they were forcing the door lever to lock the doors. The door bolts where operated from a central handle by 1/2" thick walled tubing. It didn't take much to cause them to buckle. When I got thru with it a 300 lb monkey could swing on the end of the handle and not buckle them. And only a 1/2 lb heavier. |
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Title: Re: 1986 Savage Street Tracker build Post by badwolf on 10/29/21 at 16:00:25 ALL RIGHT! TUBEING WAR! I have to guestion what you mean by strength. Tension, torsion, shear, or resistance to bending? I said to go with 1/2'' tubeing rather than 3/8'' round bar. The inside of a round bar is it's weakest point, the surface is the strongest. Because of the greater surface area, larger od and inside surface, I would go with the tubeing all day for resistance to bending. We need Dave (a engineer ) to weigh-in on this one. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 10/29/21 at 16:17:52 Hey Sneeze, the seat (and frame) and the tail light look good together. Good choice |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 16:40:26 Thanks! A little about my background... I spent the last 24 years of my working life running a metal fabrication shop as production and quality assurance manager. We did commercial and aerospace work. Contract manufacturing. I certified four of our welders for aerospace, and we were welding on patriot missle parts for Raytheon. So I will enjoy reading about this tube war. Hijack approved! This should be fun! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 17:39:39 My $0.02 on steel tubing. Wall thickness and alloy have more to do with strength than any other parameter. Rage on!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 18:29:58 My handlebars showed up this afternoon. I went with TC Bros flat track bars. Luckily they were shipped using a foam sleeve over them as the box ended up looking like it had been run over by a forklift. Thankfully they arrived straight and undamaged, which is more than can be said about that box! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 18:37:23 So I totally screwed up. My fork caps showed up from China. Search as I could, I could not find a source to ship from the US. Well, I ordered the wrong ones. Same diameter threads, but a different pitch. My bad. I think I will be hard pressed to get a return or a refund as they are not damaged and it was my fault, so I am out $25. The plan was to have them by the time the handlebars arrived so I could measure and plan out the risers. Now the bars will have to wait for the right fork caps. Sigh... :-[ |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 10/29/21 at 19:41:27 686A7967797B636A62790B0 wrote:
Dave makes targets. All have to be considered. In tension, pound for pound, tubing is the same as bar. Torsion, tubing has it over bar. Bending, tubing has it over bar. More wt., more material, more strength. The books are under the monitor, don't make take them out. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 20:07:56 Quote:
Hahaha! I love it! Don't make me pull over and come back there!!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/29/21 at 20:14:27 So I have gone about as far as I can until I get the rear tank mounting hardware. That will determine where the front of the seat will sit, and I will know how much room I will have between the fiberglass and the bike frame. I won't start tacking the seat frame together until I have all of the front mount pieces finished. It really doesn't look like 8' of round bar when you stand back. It took two lengths at 4' to this point. Another length for some bracing under the seat area should do it. I have more flat bar for the area where it will tie in with the rear tank mounting hardware, and to hang the tail light. |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 10/30/21 at 03:14:05 041B3E39333A36253C570 wrote:
That tail/brake/turn signal light looks great - but you may need to add a supplemental "brake light" that can actually be seen when you ride in daylight.....especially if the sun is shining. So many of the aftermarket LED tail and turn signal lights are just not bright enough to be seen in direct sunlight......they will not catch the attention of a distracted driver who is 200 feet behind you when you apply your brakes. I have ridden behind several motorcycles with combination tail light/turn signal LED's - and unless you are looking directly at the light you can't see it work in sunlight. The tail light that RYCA supplied for the seat I used is very similar - in my garage it seems to work fine but when you get it outside in traffic it is a different story. In order to keep me safer I added an emergency LED strobe for a brake light. These can be ordered in red and the pattern can be set for "steady on" so they don't flash. I mounted mine where the bottom of the seat meets the downward frame tubes......you can't see it when you walk around the bike but when a driver is sitting in a car/truck and 30 feet back it is in their line of sight. It is incredibly bright and likely blinding after dark - so I added a layer of red electrical tape to tone it down a bit........now I realize that adding a resistor would work as well. Here is a link for the type of LED I used for my brake light. https://ultrabrightlightz.com/products/feniex-t3-surface-mount-grille-light |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/30/21 at 08:14:30 Thanks, Dave. Did you need to change the flasher relay to get the LED's to blink as well? I used LED turn signals on my baja bug, and bought a "no load" flasher relay that claimed to solve the issue. I had 25 LED's on each circuit (12 in each indicator and one in the dash) and they still wouldn't flash. I solved that issue by putting in a side indicator under the front fender that was an incandescent bulb which created enough load to get the supposed "no load" relay to flash. |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 10/30/21 at 10:49:30 Yes, I needed to install a solid state flasher unit to get the blinkers to blink when I switched to LED units! I had purchased small turn signal units like the one below. They used a small filament bulb turned sideways in the housing and there was no reflector to help send the light out the lens - so they weren't nearly as bright as the stock units. https://www.revzilla.com/motorcycle/speedmetal-short-stalk-turn-signals?gclid=CjwKCAjw2vOLBhBPEiwAjEeK9oD2qK1_RKEpneA_do0cyfwFd3a3VcKz2oqtPG8RswYwUkHaNbMppxoCLagQAvD_BwE In converted them to LED units by installing a pair of the LED emitters into each housing. https://www.superbrightleds.com/moreinfo/led-light-modules/1-round-wired-led-accent-light-80-lumens/1141/ |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/30/21 at 12:56:38 I am starting the mods to the swing arm to fit the larger rear wheel, and cut off the brackets that are in the way of the chain conversion. Since this bike did not have the chain guard when I got it, I want to make sure I am not cutting off anything I will regret. I know the bracket at the swingarm pivot is for the chain guard, but the other circled in red I don't know what it's for. It looks like it will be in the way of the chain, and will need to come off. But what is it there for? Also, is there any issue with cutting both sides of the bracket at the pivot, or should I just cut off the top side that would interfere? TIA... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/30/21 at 14:30:22 I determined that must be the chain guard mount. The picture doesn't show it very well. Either way it would interfere with the chain, so off it came. Here is the patch panel tacked in place. Time to fit check the tire to make sure it won't touch with the axle fully forward in the slots. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/30/21 at 14:39:19 Every blind pig finds a truffle eventually. Tire clears great! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/30/21 at 16:19:17 It took some doing as the bolts were rusted in place, but I was able to disassemble the stock handlebar clamps from the risers. I am looking at reusing the clamps instead of buying new ones. So I put them on the new bars and held them up to the top triple clamp to see how they would fit. It may require a counter bore underneath to get a flat seat for a nut, and they are closer to the steering stem than before. Using this location would not only clear the new adjustable fork caps, but leave room up front to mount a gage. Considering moving the speedo up front too. Has this handlebar clamp position been used before with the lower as a top clamp? Any feedback on possible issues bringing the bars closer to the stem? |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 10/31/21 at 03:18:22 I rant into the raised fork tube/handlebar interference issue.....and ultimately decided to send my fork tubes to Gordy's Goodworks to have him shorten the tubes 2" and re-thread them. I hope to get them back next week. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/31/21 at 13:56:55 I think this clamp position will avoid any clearance issues with the fork tubes/caps. I'm just not sure if it will create any issues being that close to the steering stem. It should be okay? Haven't drilled any holes yet. Taking my time, welding a little here, then there, alternating in a criss cross pattern, I was able to get 100% weld and ground flush with no warping! The swingarm is still straight. Whew! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/31/21 at 13:57:51 Bottom side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/31/21 at 14:05:30 Another mod checked off the list! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/31/21 at 15:11:28 I have given up on CL Moto Tech and trying to purchase RFY shocks through him. I have tried sending multiple messages, and can't seem to get any response. I have started a refund request as his webstore still processes a sales transaction. So, I am back looking for rear shocks. I am trying all the usual sites and searches, so if anyone has any other recommendations (other than Ohlins - $$$$), I am all ears. Thanks! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 10/31/21 at 15:59:23 My request for a refund resulted in an email back from Chris. Turns out he is still processing my order and should be shipping them this coming week. I sure wish people in business would practice better communication. That was one thing in my career that I made sure to do - respond to customer calls and/or communication. Even if it wasn't good news I always replied to customers. So all is good on the shock front... ::) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/01/21 at 13:02:44 This is the final configuration of round bar. One flat bar still to make for across the front, which will tie into the rear tank mount. I still need to grind some chamfers before welding can begin. So some angles will move during weld fitting. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/01/21 at 13:38:41 That looks great |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/01/21 at 15:13:23 These motors sure look smaller when they are out of the frame! ;D The swingarm is in the blast cabinet. Motor is on the bench. Stripping stuff off the frame so I can get it and the other associated parts off to powder coat. Cutting down the bosses that were used for the forward foot controls. The frame, swingarm, and a few other tid bits will get done in metallic silver. Hoping to drop it off by the end of this week. The lower rear engine mount bolt came out covered in what looks like chocolate oil. All other mounting bolts were dry. :-? When I pulled the drain plug I got well over a gallon of what looked like very thin oil. Then the gas smell hit me. Yes, I am swapping out the petcock for a Raptor unit that won't leak. Time to make an engine stand and get the bench organized for the tear down. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/01/21 at 15:37:31 I’d rather tear-down your project. My winter project is an 81 CB900C which will include a complete engine tear-down and rebuild. I got it for a dirt cheap price, and the bike is in overall good condition. But it’s still a complex engine rebuild. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/01/21 at 16:04:30 I just finished a 4 cylinder bike. I'm having more fun with this one since it is in (relatively) better shape than my Kawi was. How did you relocate your kickstand? Was it part of the parts provided by RYCA? Or did you design your own mounts to be welded to the frame? |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 11/01/21 at 16:42:45 I did a RYCA style kickstand mount. You can find it on page 3 in this thread: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1487785879/30 It's not a great solution honestly. Especially the way I did it using part of the stock mount. (It was a hack!!!) I would buy a kickstand from Lowbrow Customs or similar place and weld it on. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/01/21 at 16:48:01 Take a look at the photo in my signature. The kickstand uses an existing frame boss. When I got my bike it was torn down in about 10 minutes (not an exaggeration) so I really have no idea what was there originally. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/01/21 at 18:23:09 The kickstand is part of the foot control cast aluminum bracket on mine. It was needing moving one way or the other. When I zoom in on your picture it gets too blurry to tell if it is a factory mount from a later year or something you put on. I need to address the kickstand mount on my frame before it goes out to powder coat, so it is high on my priority list. I wish I had a knee mill in my shop. And an engine lathe. One can never have enough tools. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 08:18:56 4443424446445F442B0 wrote:
Thanks for the tip, Ohiomoto. Looking at one of those universal weld on jobs from Low Brow. It looks like the best solution at this point to move my kickstand. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 09:09:50 Morning coffee and FleaBay are a bad combination! I ordered a used set of battery mount brackets that I found for dirt cheap. Then I started looking at footpeg options. After looking at the dirt bike style (all metal with "spikes"), and seeing the rubber ones Ohiomoto used, I decided the rubber ones would offer more comfort from vibration. I found a good set from an XS400 that will clean up real nice in my blast cabinet. My comment earlier about trying to get the frame and swingarm out to powder coating by the end of this week was a little overambitious. I need to get the kickstand sorted, and also the foot controls relocated. These will need to be coated the same color as the frame, so I need to cool my jets and finish what needs to be done so I can get everything coated at the same time. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 12:47:06 6F7C6B6A75787E7C7728190 wrote:
I just found the gear on FleaBay for a decent price. Hopefully it inspects out in good condition! Thanks, Versy. Still on the hunt for a new case cover. I will be hitting you up for the cam chain adjuster in the very near future... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 13:44:34 4F48494F4D4F544F200 wrote:
I found that these are for either 1" tube or 1-1/4" tube. Not sure about newer models, but my lower frame tubes are 1-1/8" in diameter. Easy fix with a piece of 1-1/4" x .06 wall steel tube. Cut a piece to length, then cut it in half lengthwise. Instant shim down to 1-1/8" diameter. The new kickstand is on its way. I will override the switch in the OEM harness to use this universal weld on kickstand. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 13:49:23 I pulled the cover off to check the starter gears. Only wear I see is on the small gear on the starter shaft itself. Definite wear marks, but no matching wear marks on the gear it meshes with. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 13:51:41 When I removed the starter clutch gear, I found there were no washers on either side of this gear. Did the earlier models not require the two washers (one on either side)? The newer gear I ordered off of FleaBay has both washers included - I checked before purchasing. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 13:53:27 Since my cover is in really good cosmetic shape, I am leaning toward keeping it and having it machined to work with the new gear. Very slim pickings online for this cover... :o |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 13:56:42 I had a random thought while pulling the side cover off. When I did my leak down compression test, I did not verify the valve clearances were set properly. Before I start pulling the top end apart, me thinks I should verify the valve clearances and perform another leak down test. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/02/21 at 14:02:22 6D7257505A535F4C553E0 wrote:
The original gear has smooth ends. The torque limiter gear has rough ends and needs washers. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 14:04:15 Thanks... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 14:19:20 It's not at 19mm yet, but it is definitely crooked to the bore. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 14:19:44 different angle |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/02/21 at 14:20:55 I found the left side engine cover was installed without a gasket. It was put on using only RTV. darn garage hacks!! |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/02/21 at 17:40:22 120D282F252C20332A410 wrote:
That's usually harder to get right, so I tip my hat to them. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 11/02/21 at 18:07:39 687752555F565A49503B0 wrote:
They do make them in 1-1/8". Maybe Lowbrow doesn't stock them or is out of stock. That said, your solution will only make everything stronger. Score! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/05/21 at 16:38:20 Out of all the tools in my shop, I love my blast cabinet the most! I get to buy my used parts all rusty and crappy looking, and make them look near new. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/05/21 at 16:39:01 After 80 grit glass bead blast... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/05/21 at 16:41:13 These are Yamaha XS400 foot pegs off Fleabay. I decided on rubber footpegs to help with the vibration. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/05/21 at 18:09:43 A blast cabinet??? Sweeeeet! Very nice. Do you have any trouble keeping the media in the cabinet? I'm surprised your tensioner is as skewed as it is. Have you given any thought into bucking up your rear chain guide with a jack bolt? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/05/21 at 18:29:04 Some minor leaks around the dust collector in the rear, and the door on the side. Not much, really. You can see the unit along the wall. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/05/21 at 18:31:26 I think the top end, at the very least, is coming apart on this motor. I will replace the chain tensioner and whatever else I find worn out. All improvement mods are being considered. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/06/21 at 16:11:49 I received the starter clutch gear today. According to my measurements, it looks like 13.25mm needs to be removed from the boss inside the case for this thicker part. Does that sound about right? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/06/21 at 16:19:04 Per Versy's thread the difference between early and late cases is 13.23mm. So my measurements are fine. 8-) I went ahead and drilled the new "lower is the upper" triple clamp to use the stock bar clamps. I removed the risers and just used the clamps. First test fit of the bars bolted up. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/06/21 at 16:19:45 side view |
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Title: Re: 1986 Savage Street Tracker build Post by Tocsik on 11/08/21 at 10:09:24 The angle of the bars as they sit now is in near perfect alignment with the slope on the top of the tank. Sweet. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 10:18:01 'Twas just a guess at this point. Everything will be adjusted during final assembly for ergonomics. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 11:03:06 6A60646E656C68613F393D0D0 wrote:
After finally getting in contact with Chris at CL MotoTech, I arranged for him to supply the 320mm shocks. They are arriving today according to the tracking. 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 12:31:27 Man, am I stoked Chris came through with these shocks! They will look great with the body in Navy Blue and the frame metallic silver. I love getting more visuals as this build keeps progressing. The kickstand should arrive on Wednesday, and some tubing for the fabrication of the mid controls sometime this week as well. My welder is about to get a good work out. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 12:31:59 side view |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 14:21:59 What happened to the tubing war??!! Maybe some more pictures will liven it back up. I started welding the seat/tail frame together, and I have to admit it is coming out better than I had pictured in my head. I haven't put the seat cross bracing in yet as I am waiting for the assembly to cool off. That way I can tweak the long legs back to where I want them. Weld contraction can be your friend, or your worst enemy if you don't plan it right. It's starting to look just like the fiberglass. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 14:23:50 Side view. I am not finished welding all of the joints yet. This is just heavy tack welds at this point. Tack, cool, tweak. Rinse, and repeat! ;D |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 14:32:42 I'm good with this! I doubt the fiberglass is this straight... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 15:06:31 Tubing war report: This frame is super stiff! More than strong enough. And it fits the fiberglass like a glove. I'm really happy with how this came out, and much, much easier to fab than trying to do this out of tubing. 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 15:08:15 Two more brackets to go. The front mount at the rear of the tank, and the tail light mount. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/08/21 at 15:44:55 Lookin good Sneeze. Those shocks look great. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/08/21 at 18:26:56 Thanks! |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/09/21 at 04:59:58 The subframe looks really, really good. It's a shame you have to cover it in fiberglass. The shocks you got from Chris are adjustable up to 330mm, so after you get the chain installed take the time to conduct a swingarm swing survey to get the shocks at the perfect length. You will find that as you run out of travel, the chain will also tighten. The chain will get so tight at the upper end that the wheel may stop turning. Obviously you'll want to have good margin on that. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 07:29:27 The sub frame will be powder coated silver to match the main frame and swingarm, and the underside of the fiberglass will be the same royal blue as the body. So it will stand out if you look under her skirt! :o Shock length fine tuning will happen after the motor is back in the frame, so I can wrap the chain. There is a bracket on the bottom side of the swingarm that I may need to trim off - it's about 6 - 8" back from the pivot if I recall. Not sure what it was supporting, but it may interfere with the chain? Still lots to do before anything goes off to the powder coater. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/09/21 at 10:21:30 If this is the offending bracket in question, it is a mount for the lower belt guard. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 10:35:05 I wasn't aware there is a lower belt guard. This bike is missing an awful lot of the stock trim. That bracket on my swingarm is currently on the endangered species list. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/09/21 at 10:43:25 I have spares of both belt guards. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/09/21 at 11:27:48 I did a lot of de-tabbing of my swingarm. Enough that I sent it out for powder coating. My chain guard is a RYCA fabrication that can be easily copied. It is attached to the rear frame stay (see the photos) |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/09/21 at 11:28:09 And another |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 14:48:24 The front mount got a bit complicated because the seat frame was on a different plane than the rubber isolated rear tank mounts. So I made a wedgie! A built a bracket for both planes, welded them together, and counterbored the top holes for the rear tank mount screws. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 14:51:33 A simple piece of 2" steel angle fit the bill for the tail light mount. I used the plane of the tail frame which helped angle the license plate mount a little farther up. I still may need to do an adjustment to that angle later depending on tire clearance. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 14:52:32 The tail light assembly is nice and tucked under the tail section. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 14:57:48 With the tail light bracket installed, the seat/tail mount frame is pretty much done. I still need to get the rest of the holes drilled through the fiberglass to hold it to the metal frame. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 15:21:50 Since my postal scale only goes up to 5 lbs., I am guessing the frame weighs in around 6 - 7 lbs. The scale errors out just before I let all the weight onto it, that's my best guess. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/09/21 at 16:24:52 Using the bathroom scale, the seat/tail frame is 5.8 lbs. So to those that engaged in the tubing war, the effort to bend tubing (I don't have the tooling), and get it TIG welded (I don't have a TIG welder, and don't know how), in my opinion is not worth a couple of pounds in weight savings. I can stand on this frame without any deflection, so strength is not a detraction to it's intended use or performance. |
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Title: Re: 1986 Savage Street Tracker build Post by Carsower on 11/10/21 at 08:52:37 647B5E59535A56455C370 wrote:
FWIW I bought a tail light assembly that looked exactly like that off amazon last summer. It filled up with water the first time I rode in the rain and shorted out. Leaving me with no tail light in a rain storm a long way from home. I think the brand I bought was ANIKA. I'm running the supernova pin lights from revival cycles now and love them. Brake lights are so bright they are almost painful to look at. And they are very clean mounting. Just a bulb on a 8mm stud. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/10/21 at 09:21:02 This unit was advertised as waterproof. Since I have no intention of riding in inclement weather, it shouldn't be an issue (and probably won't be tested!). |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/10/21 at 10:36:24 7B594A4B574F5D4A380 wrote:
This one? https://revivalcycles.com/products/led-light |
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Title: Re: 1986 Savage Street Tracker build Post by Carsower on 11/10/21 at 14:29:13 Yup! Those are the ones. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/10/21 at 15:37:33 My Low Brow Customs kick stand showed up today. Here is a couple shots comparing it to the stock unit. Since I am removing the forward foot controls, and the return spring broke from corrosion, getting a new kick stand made sense to me. The angle and length of this universal stand is almost identical to the stock one. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/10/21 at 15:38:09 overlay view |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/10/21 at 15:39:48 Now I need to wait for my material to show up so I can start determining the position. Time to put the wheels back on in the meantime. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/10/21 at 16:42:50 She is a roller once more (but only temporarily). I am certain this won't be the last time I put it together and take it back apart before final assembly. My material I am waiting for is for the mid mount construction of the foot controls. Now I can work out the kick stand placement along with them. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/10/21 at 17:02:43 Using an old m/c plate and mounting it as high up to the tail light as possible, there is only 1-3/8" of clearance to the tire. The wheel is as far forward in the axle slots, and the shocks are at the shortest length adjustment. The bend in the plate bracket needs to increase to avoid contact at full compression. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/13/21 at 12:45:18 So with the bike upright, and the kick stand down, how much space is there from the bottom of the kick stand to the ground? I'm trying to determine the angle of the new stand so I can weld it on. If someone could take a measurement of theirs I would appreciate it! I am thinking about 2"... I was wondering how thick the wall is on the lower frame tube, also. .090"? .060"? I am sure it isn't as thick as .125" due to weight reasons. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/13/21 at 16:08:40 The nearly stock bikes each rested easily on a 2x4 and with wheels straight, nearly balanced with 2 2x4's under the kickstand. Probably 1/4" less would've worked. I'd have to guess that the tubing was about .06" |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/13/21 at 17:31:30 It's always fun setting up to weld a really thick piece to a thin wall tube. Don't want to blow a hole in the tube, but need good penetration into the thick piece. Need to set it hot, and favor the thick piece without blowing through. Yes, it would be easier to manage the heat with a TIG weld, but that means taking the bike elsewhere and spending more money. I finally got my fork caps from China. Now I can fill the forks and be done with them. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/13/21 at 19:29:47 initiate the weld on the thicker piece and keep that distance along the weld. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/14/21 at 16:07:49 I know this is kinda late but have you considered a no-weld option? I believe Armen installed a stand off a Triumph. It looks good to me. Very similar to your stand but the bracket bolts on. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/14/21 at 16:08:27 This is the stand sans the bracket. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/14/21 at 16:08:45 My welds aren't pretty - glad I have a grinder! I now have a kick stand again. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/14/21 at 16:09:14 Up position |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/14/21 at 16:10:43 51575824262125150 wrote:
Yeah, a bit late... ;) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/15/21 at 12:39:28 Finally off the lift and officially standing on her own. The lean angle is just a little more than I wanted, but not too severe. We will see how it rests after the motor is back in and the rear suspension is adjusted. The stand is getting a serious cleaning and the Kawi is going up next. I will be back at the tracker build soon. |
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Title: Re: 1986 Savage Street Tracker build Post by Tocsik on 11/15/21 at 15:10:05 Lookin' good. Pretty fast progress on this. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/15/21 at 16:29:50 Yeah, not bad for a month and a half! Seems like longer when you have to wait on shipping for everything. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/21/21 at 14:50:07 I hit a snag taking my forks apart on my Kawi, so I ping ponged back to the Savage build. Decided to take the cam cover off and start the motor disassembly. Well, it was not unexpected... I didn't get very far to find out this will be a total tear down. Cases will will need to come apart and every bearing/seal replaced. Along with a new camshaft!!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/21/21 at 14:50:40 The other lobe is not much better... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/21/21 at 14:52:00 I'm starting to read the hop up threads. 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/21/21 at 17:30:21 Don’t feel bad, this is the status of my winter project. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 11/21/21 at 19:14:53 4D5277707A737F6C751E0 wrote:
caused by idling too long on the kickstand. the tilt drains half the tub and the upper cam starves for oil. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/21/21 at 19:20:34 Interesting. I never would have come to that conclusion. Since I have no idea when this motor last ran, I am crossing my fingers I don't find more damage adding to the "replace the part" pile. |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 11/22/21 at 02:32:58 The bottom end is tough.......the cam lobe wear is pretty typical of a bike that is idled to long and/or run with oil that does not have enough ZDDP to keep the cam and rocker happy. I wouldn't be too quick to condemn the bottom end bearings. Lots of our forum members fix the cam/rocker issues and then start running good oil (Rotella), and the engine continues to run happily. Any metal that came off the cam/rocker went into the sump and through the filter and never got to the bearings. You didn't send a photo of the rockers - but I suspect you have the rockers without the hardened pads (2005 and later). When you order new rockers be sure to get the 2005 and later rockers. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 10:50:16 Rockers |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 10:54:08 I am not opposed to shipping the cylinder head to be rebuilt. Any recommendations on a good shop that knows how to do these heads properly? Thumper Racing closed - they were in town near me. They specialized in four stroke singles. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/22/21 at 14:51:48 It wouldn't surprise me if your cylinder head is just fine as-is. From what I see here, you have excellent skills. I think you are more than capable. Take it apart, clean & inspect, install new guide seals, leak test it, rock & roll. You might wanna breath on them ports a bit while you have it apart. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 15:37:23 I am not going to invest in the tools required to cut new valve seats. I would prefer a professional three angle cut. The leak down compression test showed most if not all loss was the exhaust valves. If I am going to a new cam, new rockers, piston, etc. I would be more comfortable with a shop head rebuild than attempt it myself. I am going to start looking for a carb replacement and exhaust options. Thanks for the PM - looking forward to seeing more. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/22/21 at 16:12:26 Use a machine shop for the angle cut. Otherwise this is a remove and replace operation. It’s also a very good opportunity to open the exhaust port. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 16:26:37 I have never done any porting myself, but certainly not opposed to it. Any detailed info on where to remove material? Just match port to the exhaust, or polish out the entire exhaust track? I know it's better not to polish the intake to keep the atomization up entering the head. Once the motor is back in the lean will decrease some (not much). I would have gone a little less, but what is welded is welded. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/22/21 at 16:49:11 Hey Sneeze, I blew up your photo of the rocker arms. It's blurry but looks like you might have some chipping on the tips of the adjusters. Can you take some photos of your valve tips and post them? Also, can you try to get some clear close-ups of the tips of your adjusters? Post those too. Regarding your valves. Put a spark plug in the cylinder head. Turn it over and level it out. Then fill the combustion chamber with mineral spirits. Monitor the ports for leakage. If you have any significant leaks, it will be evident when you look in the ports with a flashlight. Any decent automotive machine shop can cut your seats, but you might not need to do anything to the valves or seats. Leak check them first. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 18:02:54 The results of my leak down compression test indicated to me that the valve seats could use a recut and the valves reground. Here are some closer shots. The adjustable tappets look like they are fine, but the surfaces that ride on the cams are totally shot. The ends of the valves look good, with no unusual wear patterns or chips. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 18:03:21 other valves |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 18:03:58 tappets |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 18:04:31 other tappets |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/22/21 at 18:05:26 This is pretty bad wear in my book. Going with the newer year hardened ones. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/23/21 at 07:51:39 332C090E040D01120B600 wrote:
Our very own DragBikeMike has done extensive testing on porting the LS650 head: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1627891507/0 If you are a member of ThumperTalk, I would also suggest reading the lengthy discussion started by Mixxer: https://thumpertalk.com/forums/topic/1315803-porting-the-final-limiter-to-all-components/ |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/23/21 at 07:56:26 I just finished reading DragBikeMike's Evolution of a hot rod thread series last night. Very impressed with his approach and documentation of all the research he has done. Gary - looks like you posted a duplicate link to Mike's cylinder head thread. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/23/21 at 11:12:19 So I did. I corrected the post above |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/23/21 at 12:15:30 I agree Sneeze, your adjusters and valve tips seem to be OK. I still think you should do a leak test with mineral spirits just to see what you can learn. It's quick & easy. As previously mentioned by others, excessive wear of the cam & rocker pads is not uncommon. Your engine is very old (like 35 years old). That is why I think you should leak test it, disassemble it, and inspect it. IMO, if your valve guides are shot you would be better off finding a good used low-mileage head. Only way to find that out is take it apart. Also, if you plan on porting it, disassembly will be mandatory, and you want to finish the ports before any valve seat work. That way you won't rat-bite a nice freshly cut seat. If tooling is a problem, check out these el cheapo spring compressors. If you fish around on Amazon you can actually find them for as little as $16 bucks. Our LS650 has 30mm spring retainers. https://www.amazon.com/DASBET-Solid-Spring-Compressor-Service/dp/B074ZHY3WJ/ref=asc_df_B074ZHY3WJ/?tag=hyprod-20&linkCode=df0&hvadid=241954052572&hvpos=&hvnetw=g&hvrand=5240805410061875271&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9032800&hvtargid=pla-450740252071&psc=1 Mr. Gary, muchos mahalos for the link to Mixxer's Thumper Talk post. Very nice indeed. Haven't read it all yet but it looks first rate. Man that 400 has killer valves. We can only dream about those. They look like 38s. Do you happen to know what size they are? |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/23/21 at 20:27:08 Mike, The DRZ valves are 36mm for the intake and 29mm for the exhaust. 1mm Oversized titanium valves are available from Kibblewhite. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/24/21 at 13:39:17 I got the head off. Cylinder wall looks good. A light hone would be all it needs, if anything. Cross hatches still visible all the way down. They get a little faint in places, but still visible. I have some denatured alcohol for a leak down on the combustion chamber, but I must have thrown out the old spark plug. I have to go fetch a new one to seal the combustion chamber to do the leak down. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/24/21 at 13:54:24 Now comes decision time. Repair the damaged bits with stock replacements, or step off that slippery slope of performance mods. I think this motor would fire up and run fine with a valve job, new cam, and new rockers. Or go with a DR cam, PWK38 carb, porting, HC piston & rings, and a larger header and muffler. I want to wish all of you on the forum a Happy Thanksgiving! If you travel, be safe, and if you are with family, enjoy every minute. Time is fleeting, don't waste it... 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/26/21 at 09:15:52 Not sure I have mentioned this earlier in all of my posts, but the speedo on this bike has logged just under 10k miles. No way of being certain that is accurate, but the condition of the cylinder wall makes me tend to believe it's a true number. If my local m/c shop is open today I will pick up a spark plug and do the leak down test using some denatured alcohol. With the leak down compression test showing a 60% loss at 30 psi, I suspect there will be a substantial leak passed the exhaust valves. This is where the air pressure loss was coming from - out the exhaust port. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 11/26/21 at 13:55:56 My advice, port and polish the head as described by Mike, and replace the position with the 94mm flat top. Now is the time. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/26/21 at 15:08:31 I ordered the DR cam, late model rockers, and a low cost valve spring compressor. Leak test with alcohol is underway. The rim of one exhaust and one intake valve show a light amount of "wet", but not enough to run down the port. It will be next week before the valve spring compressor shows up. Maybe just lapping the valve seats will suffice? We will see if the guides are worn past the limit after I get the valves out. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/26/21 at 16:19:10 Three out of four valves are showing signs of leaking. The two exhaust valves have a damp ring around the valve seat edge. The right intake valve is the worst, it has a trail of fluid down the port to the intake boot, leaving a puddle there. I'm not going to consider only a lap at this point. If it's coming apart this far might as well just do the whole valve job. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/26/21 at 16:19:35 intake |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 11/27/21 at 02:28:17 Before you take the valves out.....consider cleaning off the carbon this way. You can level up the head and clean the combustion chamber.....then turn it over and clean the exhaust port by filling it up. https://www.youtube.com/watch?v=voe-ZcKjg4Y&t=17s https://www.youtube.com/watch?v=IEyus9alwIY https://www.youtube.com/watch?v=bRiZOTTel34 |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 11/27/21 at 13:19:06 Cool info on the carbon removal Dave. Thanks. I'm gonna see if I can find any of that Berryman's dip. Sneeze, it's interesting that the leakdown test done with air showed big leaks at the exhaust valves, but the leak test done with alcohol revealed the intakes to be the leakers. I can't wait to see what you find when you get those valves out. Is it possible that the exhaust valves were adjusted too tight when you did the air test, or the engine was possibly at TDC on the exhaust stroke? Your test medium (alcohol) is about as non-viscous as you can get. It would be pretty hard to get a perfect seal with alcohol. I see you have valves with reduced diameter stems. I found those on the eBay head I used for my last project. Never had seen them before. Now here we see them again. Cool. Hang on to those if they are in good condition. As I recall, the intakes seem to flow a bit better. Hey Gary, 36s on a 400. Killer. No wonder they get so much power out of those dirt scoots. Three-millimeter larger intakes, 250cc smaller engine, 17 more HP. What's not to like about that? ;) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 13:26:46 I verified that all the tappets were loose when doing to leak down compression test, so no pressure was on the valves. I also verified the timing marks, and physically verified the piston was at TDC. I could barely feel anything coming out the intake boot, but could definitely feel airflow coming out the exhaust port (and hear it, too!). I was quite surprised to see that flow out the intake valve, and very little out the exhaust. I should have no problem finding that parts dip here in Nevada. They aren't very strict on chemical sales in this state. Valve spring compressor is arriving next Wednesday, as is the carburetor. Cam and rockers do not have an ETA established yet. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 13:29:26 If the exhaust valves were even partially open I doubt I would have seen only 60% loss at 30 psi. It would have been 100% loss and wouldn't have built any pressure at all. That's my view, and I am sticking to it! 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 14:46:08 This is the carb that came with my bike (not on it). It was still connected to the throttle and right switch controls though. I assume this is the stock carb for an '87 Savage? The only marking is the Mikuni Corp. on one side, and a partial Made in Japa on the other. No numbers or identifiers. The ID of the intake side is 40mm - model should be BS40SS per the fsm. I dug it out of my parts shelf to check the OD for comparison on the PWK40 I bought. This carb is 48mm OD at the boot. The PWK40 is listed at 46mm OD at the boot. Are there different diameters of PWK40's? Is the OD on the new carb going to work with the stock boot (I have a new one)? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 14:46:47 boot side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 14:47:09 side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 14:47:29 filter side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 14:56:34 If this is the stock carb, there is a 1mm interference with the boot ID. The new carb with have a 1mm gap. I think I may have bought the wrong carb. :-? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/27/21 at 19:06:08 I went back and re-read some of DragBikeMike's carb thread, and found that with the right clamp it will work fine. Didn't sink in the first time I read it. My wife says I have two main faults. I don't listen, and some other thing... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 10:32:08 Spring compressor arrived earlier than expected. The head will be disassembled and the cylinder and piston removed today. Pics to follow later! 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 12:30:03 The first valve I removed was the intake that leaked the most. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 12:30:36 valve |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 12:36:19 The last exhaust valve felt bad coming out. I shouldn't have pulled it all the way out with what I was feeling, but did anyway. I probably damaged the guide doing it. After inspection there is a very small burr on the edge of the keeper groove, on the side closest to the valve end. This valve had the keepers stuck on the spring retainer and finally popped with pressure from the spring compressor. A couple others popped off as well, but not as loud as this valve. I will inspect the keepers thoroughly after cleaning. The valve stem needs some filing with a machinists file to remove that burr. I'm thinking I will need to put in new guides and seals. All of the valve stems measure in spec on the stem OD. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 12:37:48 intake seats |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 12:38:20 exhaust seats |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 12:38:50 chamber |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 13:02:37 The piston looked surprisingly well, with the exception of a small spot on the skirt. Forging flaw? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 13:03:12 piston rear I found water on one of the cylinder studs. Weird. In this climate our humidity averages around 20%. This bike has been in my shop for over two years. I would have thought any moisture would have evaporated by now. I can only think it is rain accumulation from the previous owner. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 11/30/21 at 13:03:37 piston front |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 11/30/21 at 17:14:37 The stock piston is cast.....not forged. The goober on the skirt is likely some corrosion from sitting. I wouldn't worry if the burr made a scratch on the valve guide.....it won't cause any harm. (Be sure to smooth it out before you put the valve back down the guide). |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/01/21 at 11:36:07 I got my PWK40 in the mail today. Unlike DBM's that actually measured 38mm, this one is at 40mm on both ends. Hopefully I can jet this one to work well. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/01/21 at 11:36:50 filter side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/01/21 at 11:37:14 engine side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/01/21 at 11:41:47 It's hard to believe these are going for only $39.99. After a thorough inspection, the only fault I can find is it having a kinked hose upon arrival. Easily dealt with, though. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/02/21 at 16:24:14 Hey Sneezy, just a tip. Before I try to remove an old valve, I dress down the edges of the cotter groove with an oil stone. Just enough to knock off any burrs. You might want to just touch up that guide with a 7mm ball hone. Just a touch up, a few strokes, not enough to enlarge the guide. You weren't twisting it back and forth as you removed it, were you? Hold the head up to a light and do a visual inspection. The seats and valves look pretty good. You should clean them up with a scotch-bright pad soaked in oil. I like to spin the valves in a drill press while I apply the scotch-bright pad. It does a nice job. Once you get them cleaned up maybe reassemble and try the leak test again. I would use a solution of mineral spirits with 10% motor oil. If they only weep I would leave em alone. There's only so much material on the valves and seats. Your carb looks pretty sweet. Who did you buy it from? It is different from mine. There is no notch in the needle jet hood. Mine, like yours, was bigger than 38mm at the outlet, but the venturi was only 38mm. I'm curious who you bought it from. We should start trying to keep track. There are a lot of variations that seem to be available. I guess it comes with the territory on these questionable pedigree mixers. The quality on yours looks top notch. This is the hood I am talking about. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/02/21 at 16:26:47 All of the PWKs I have bought had a notch in the hood, like this. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/02/21 at 16:40:16 Yeah, mine doesn't have that notch. I bought it off Fleabay. I would have to go back and look at who the seller was. The Keihin label states PWK38, but the barcode label reads PWK40. Probably used a box for the 38 to ship the 40 in? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/02/21 at 18:59:29 The Ebay seller on mine was blackhary7. Ship point was inside the US - Rowland Heights, CA. |
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Title: Re: 1986 Savage Street Tracker build Post by Ruttly on 12/03/21 at 10:31:13 7F79760A080F0B3B0 wrote:
That looks a little crude. Some say it gives a crisp throttle response. I’ll usually cut / file a “V” in the hood and I’ve seen the opposite , inverfed. Either way it’s supposed to aid in atomization. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/03/21 at 12:14:41 Got some good news! The cylinder is .002" below the service limit at all 6 measurement locations. As soon as it's cleaned we will see if there is a ring lip. But it's looking like a light hone will be all it needs. :) It's a small world up here - the shop that did my Kawasaki 750 head job and cylinder bore closed shop. I found another m/c machine shop closer to my home, and it turns out it is owned by one of the ex-employees who ended up buying most of that shop's equipment when it closed. It is very likely that the guy running the new shop actually did the work on my Kawi stuff. Go figure! As soon as the piston arrives he will hone it to match the clearance. in the mean time, my DR cam and late model rockers are in transit. Just got notification that they have been shipped. Now to find a decent DR clutch... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/04/21 at 14:52:57 I love getting parts in the mail! Feels like an early Christmas present. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/05/21 at 01:10:07 Oh, those look nice Sneezy. Note that there are no oil holes in the cam lobes. The first one of these I installed I was nervous about those holes. I planned on drilling my own but got cold feet. As it turned out it hasn't been a problem. It's been runnin just fine sans holes. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/05/21 at 15:00:50 So now that replacements for damaged parts, and improvement parts are coming in, I thought I would summarize what changes I am doing to this engine/bike. It helps me keep it all straight in my pea brain! Also if the resident brains on this forum see something I left out they can chime in. Hopefully I have it all covered. In no particular order, here is what is happening to the engine and bike: ENGINE 94mm Wiseco/Lancer HC flat top piston (improvement) '95 DR650 camshaft (damage replacement & improvement) '05 LS650 rockers w/ hardened pads (damage replacement & improvement) '95 DR650 clutch (improvement) '95 LS650 starter torque limiting gear (improvement) Cylinder head porting (improvement) OEM Valve guide seals (don't trust the age of what is there) Valve seats/valves (just lapping, or cutting new) Valve end grinding/clean up (length tolerance permitting) Keihin PWK40 carburetor & jetting K&N pod filter Mac exhaust (already have a line on a complete system) Verslagen cam chain tensioner Verslagen head plug w/ o-rings new gaskets and o-rings as required for parts that came apart Engine painting (which parts TBD) CHASSIS RFY rear shocks reworked by CL MotoTech Adjustable fork caps Stock lower triple clamp used as upper Front forks lowered ~1.00" - 1.25" 18" front and rear wheels w/ Buchanon aluminum rims & SS spokes 530 chain/sprockets conversion Mid controls w/ Yamaha SX400 foot pegs Fork brace Airtech fiberglass seat/tail section LED tail light/turn signal assy Swing arm clearance for larger dia. rear tire Lowbrow universal kickstand w/ internal spring (clean!) Flat track handlebars Tachometer/speedo in front of the bars (still debating this one) Powder coated frame & swing arm Bodywork & paint on tank, side covers, and tail There is probably something else I am forgetting, but that seems to be the majority of it. All of this from a non-running parts bike that has sat for God knows how long. The clock shows 9500+miles, but who knows? With how clean the cylinder and piston look, I am tending to believe the clock. I got it without a title, so Nevada requires a bond title for 3 years before I get a clean title in my name. In that 3 years it cannot be sold out of state. As with most of my projects, once I get started I tend to go all out. Something very satisfying about bringing back a turd to life, even more so in a style that is completely different than what it started out in life! This project has an estimated time line of completion next Spring, or Summer at the latest. 8-) A huge shout out to everyone on this forum for your help, suggestions, and advice. I am not sure what to expect when it drives for the first time as I have never ridden one, let alone heard one in person. I have only heard a video of one running. darn the torpedoes... full speed ahead!! |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 12/05/21 at 16:14:10 I never rode an S40 until I was finished modifying mine. Coming from 100+ sport bikes I had my concerns…up until I twisted the throttle and felt the torque of a gigantic single and that loooong first gear. If you grew up on old Honda XL/XR’s than you’ll love the power delivery of the big single. The sweet spot for the engine is 40-60 mph back roads. While I have many bikes, I never tire of riding the Savage. |
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Title: Re: 1986 Savage Street Tracker build Post by Ruttly on 12/09/21 at 10:35:58 I swear when I’m riding my Savage the more I open the throttle the bigger the smile. Nothing like a big single , primitive , the essence of motorcycling. |
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Title: Re: 1986 Savage Street Tracker build Post by zipidachimp on 12/10/21 at 02:23:25 Shouda, coulda, woulda: Gary and Rut's comments would have stopped me from selling my 2nd S40 last year. Day late and a dollar short as usual, still hurting! Cheers! >:( |
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Title: Re: 1986 Savage Street Tracker build Post by Ruttly on 12/10/21 at 03:20:22 One will come your way , only when you least expect it ! |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/10/21 at 09:41:50 If you score that Mac exhaust system, you can tame the muffler by installing ceramic packing. It's not too difficult and it sounds waaaaaaay better. No reduction in flow either. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1606589360 You should have a real HotRod on your hands when it's all finished. Totally cool ride. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/10/21 at 10:28:24 Thanks, Mike! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/14/21 at 09:15:13 Looks like it's time to light the fire and kick the tires! Usually takes about an hour to warm up the shop with my wood stove. Not supposed to stop snowing until later today. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 13:59:39 I finally took apart my new PWK 40 carburetor. I am starting to understand why it was so inexpensive. Float bowl sealing surface is pretty rough imho. There seamed to be a micro thin layer of rtv on it even though the bowl has a o-ring. None of the jets have any identifying markings on them. The needle has no markings, either. Time for all the pics... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:00:14 No jet sizes stamped anywhere |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:00:46 internals |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:01:16 It doesn't look like the needle seat is replaceable? Maybe it is a press fit? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:01:49 A lot of rough handling marks/dents |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:02:21 O-ring sealing surface not very smooth or blemish free. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:02:48 Other side of o-ring surface |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:03:12 Some mold flashing on the tip of the point |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:03:34 another angle of the flashing |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:03:58 carb throat - engine side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:04:18 carb throat - air intake side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:04:50 close up of internals. From the shoulder in the needle the length is 46.00mm, and the taper starts at 2.66mm and reduces to 1.77mm. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 14:05:17 No washer between slide and needle clip |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/18/21 at 15:07:29 Thanks for the pics Sneezy. As far as I can tell, yours is pretty much a carbon copy of mine. With the exception of the absence of a notch in the needle jet hood and the absence of markings on the jets, it looks the same as mine in every respect. No sweat on the jet markings, you won't be using them anyway. You mentioned there is no washer under the needle clip. That is how it's supposed to be. Don't try to put a washer under that clip. If you do, you will wreck the clip. Don't ya love that cheap plastic idle stop. I think we need to be careful with that. I bought a metal replacement, but I noticed that the parts list shows a plastic idle stop for chrome plated slides, and a metal idle stop for non-chrome plated. I'm leaving the plastic stop screw in place. I have to screw it waaaaay in to achieve my preferred idle speed (1400), but I don't want to be chipping chrome and causing a sticky slide. Always better safe than sorry. Years ago I had an idle stop screw break off on a VM. It was installed on a little Yamaha YZ100. That chunk of stop screw went through the reed valves and into the engine. Ruined the whole darned thing. That can't happen on the PWK, but fragments of chrome can get chipped off and get between the slide and carb body. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/18/21 at 15:54:25 I was thinking of taking an exacto knife and trimming off that flashing making the taper end where it should. It is not an even piece of the part design. The slide has a lot of small nodules in the plating. Bot smooth on the curved side. Real poor plating quality. I had a lot of dealings with metal plating shops during my career. Not hard to recognize poor quality in that regard. I hope it doesn't start to peel or blister anywhere. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 09:46:02 This is a shot of how rough the plating is on the slide. DBM - your slide looked very smooth in comparison. I was thinking of hitting this with some really fine wet/dry sand paper to smooth it out more. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 10:06:20 After disassembly, I noticed the cam chain guide had an unusual kink in it. I was careful during the removal, so I don't think I did this to it. Looking at the part diagram it doesn't look like it should be there. Should I straighten it, or replace it? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 10:06:46 better view |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 12/20/21 at 10:40:20 100F2A2D272E223128430 wrote:
The only issue I know of is one shed it's plastic and clogged the oil pump. So if it doesn't have any cracks before and after straightening... go for it. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 10:42:52 Thanks. I figured nothing to lose trying to straighten it, if it develops a crack a new one will be ordered. Not sure how it got that way. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/20/21 at 11:42:05 That slide is ugly to the fourth power. Got any more pics? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 11:45:21 The other side isn't any better... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 11:48:27 Plating void. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 12:48:40 I started to examine the rest of my PWK parts, and found this after noticing one of the floats seemed "wet". |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 12:50:12 Okay, so there is a hole at the injection mold site. Flip it over, and found this crack!! I guess I need to find a supplier to buy a new float now. :o |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/20/21 at 12:57:09 I found a complete rebuild kit for the PWK on Fleabay for half of what I paid for the whole carb. It includes the float. Now I have more spares. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/21/21 at 17:09:04 Wow! That float assembly looks ugly too. I don't know which is worse, the float or the slide. I'm puzzled by the liquid. Did you fill it with gas? I was under the assumption that you haven't tried the carb yet, so where did the liquid come from. I went back through your prior photos and if you look closely you can see that crack. Great that you were able to find a cheap replacement. Hope it's better than the one you have now. I suppose you will be changing the slide. You will need a #7. They come with various cutaways. This picture should be helpful. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/21/21 at 17:10:35 Can you measure the slide you have now? A #7 slide has a .385" cutaway as shown in this sketch. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/21/21 at 17:13:58 Just put it on a flat surface and check it with drill bits. A #7 is right about a letter "W" drill bit. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 12/21/21 at 18:00:56 I've been in a bunch of those PWK carbs when I raced moto and the pictures you posted DON'T look like Genuine PWK parts. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/21/21 at 19:12:00 It is clearly a knock off. I have not used it or put any fuel into it. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/21/21 at 20:06:00 I measured the slide and it is a #7 slide. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/21/21 at 20:12:34 It looks like the rebuild kit I bought for the float also includes a slide as well. This kit was $15 on Fleabay. If it isn't a #7 slide in the kit I will hunt down a direct replacement. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/22/21 at 08:52:34 I got a nice score yesterday from a guy that just happens to live 30 minutes south of me. He had a lot of spare parts (mostly used) that he was giving away for free. Sorry, I just couldn't pass it up! I cherry picked through the stuff, and left most of the big items (frame, wheels, etc.) I did get a much cleaner tank, stock front fender (not sure I will use it), a bottom end motor (cases are split open) a lot of electrical items, several cables, and a stock carburetor. I ran a search and found the engine is is an '86. I was hoping it was a five speed trans, and I was after a spare head as well, but it was not to be. The top end was gone from the connecting rod upwards. Despite some of the disappointments it was a great find and you just really can't beat free! The tank is in way better shape than mine and appears clean inside as well. Mine has a couple dents and is rusty inside. He has more stuff, several seats, the rear seat bar, rear fender, aluminum fender rails, etc. If anyone is looking for any of that I would be happy to go pick it up before he moves. Just give me shout on here and let me know what you need. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/22/21 at 23:39:41 When I saw gdrseeker's post in the marketplace I thought you might go for it. Both in Nevada. Sweet deal for you Sneezy. Nice of gdrseeker to fix you up. That carb kit is almost as good of a deal. How can ya beat $15 bucks? Let us know how the quality is. I still can't figure the liquid oozing from your float. That's totally screwy. When you get the new one, you should put them both in a pan of gas and see if they have the same buoyancy. Hey Ohiomoto, when you state that "the pictures you posted DON'T look like Genuine PWK parts." Is there something different about the geometry or are you speaking strictly in terms of the quality? If there are dimensional variations or variations in geometry of the slide it would be beneficial to know what to look for. We've pretty much figured out these things are knock-offs. But you can make one run good with a little effort and they sure are cheap. Probably not the best choice for someone with limited skills and/or no tools, but with a little luck the average shade tree wrencher can make one of these knock-offs run great. |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 12/23/21 at 03:52:26 Can you please count the number of teeth on the crankshaft drive gear and clutch basket for me please? The parts list for the 86 shows the bike to have a different ratio than the later bikes - but we haven't been able to confirm that they didn't change it before they started building the bikes. Nobody on this forum has ever seen one of the gear sets with different ratios. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/23/21 at 08:02:22 As soon as I am done with my coffee, I will get out of my jammies and bunny slippers I will get a teeth count for ya! (I know, TMI!!!) ;D |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/23/21 at 08:21:08 I live on the north east end of Carson Valley. gdrseeker is on the south east end of the valley, only a 25 minute drive. Go figure! I never thought I would run into another Savage owner so close considering how remote we are. He is moving soon - I may go back and snag some more of his stash before he bails. This valley is one of the most beautiful places, but I am sure he has good reasons for leaving the area. This is my view off my front porch. Immediately over the ridge line of the Sierra Nevada mountains lies Lake Tahoe, about a 35 minute drive from my house. |
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Title: Re: 1986 Savage Street Tracker build Post by verslagen1 on 12/23/21 at 09:45:07 Should be obvious. reportedly, you are able to remove the primary gear before removing the clutch basket on an 86. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/23/21 at 10:27:41 Crankshaft drive gear = 36 teeth Clutch basket = 68 teeth Y'all should thank me for not posting a picture of me in my jammies and bunny slippers. Just sayin' ;) |
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Title: Re: 1986 Savage Street Tracker build Post by Ruttly on 12/23/21 at 20:04:53 I dare ya ! |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 12/24/21 at 04:23:55 302F0A0D070E021108630 wrote:
Well that appears to be the "first set" of confirmed early primary gears (unless my memory is wrong). The 1986 4 speed was supposed to have the 68/36 ratio....the later bikes had a 67/37 ratio. If you install the later gear set into this engine you will get a bit taller gearing (longer legs). Perhaps Suzuki made this change to reduce the rpm at cruise on the 4 speed bikes. (I do need to go out and count my 5 speed gear sets to make sure I am remembering this scenario correctly , as I gave up trying to find these mythical gears several year ago). |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 08:03:40 I was actually hoping this used bottom end was a five speed. But the serial number confirmed it to be an '86. I will have to go count the teeth on current motor, which is a '87. I suspect it has the same tooth count. If you are interested in this set just let me know. I should be receiving my Mac exhaust around the beginning of Jan. Thanks, Bill! I guess I better get off my butt and start the mid controls and get the frame off to powder coat. Looks like the engine will be ready to go back in the frame by Feb. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 12/24/21 at 08:08:11 DragBikeMike, most of the PWK pictures floating around here look like they might be cheap knockoffs, but I really don't know so take it for what it's worth. If my memory serves me correctly I always thought the Keihin PWK carbs were a nicer quality than the Mikuni carbs. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 12/24/21 at 11:38:28 Ohiomoto, Yep, they are cheap knock-offs. We got that figured out a long time ago. But with a little effort, you can make em work good. They only cost about $30 bucks. I also might add that the three PWKs (all knock-offs) that I messed around with were all good quality. So good in fact, that I mentioned in my carburetor shootout (3/28/20) that although the PWK was of questionable pedigree the quality appeared as good or better than the VM. It's crazy. The knock-off artists seem to be very talented. But for $30 bucks sumthin's gotta give eventually, and it looks like Sneezy won the lottery. His funky slide and perforated float look pretty bad, but the rest of his mixer looks fine to me. We'll have to see how it runs. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 12:13:17 As I suspected the '87 motor tooth count is the same as the '86. I wonder what year they changed over? The same year they switched to a five speed gearbox, probably. I am going to be going with a DR650 clutch mod to avoid any slipage with the hop ups I am doing, so this is a bit moot. But now I am wondering what ratio is on the DR setup? I don't believe I read in DBM's clutch thread that the crank drive gear had to be replaced too? I need to go back and research that before I buy the DR clutch. I am sure DBM covered it, so it's probably the memory acting up again. Where's my walker??!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:06:59 Even right before Christmas, USPS came through. I'm surprised! I got my rebuild kit for the PWK, and also got my jets from Jet-R-Us. First thing I noticed was not much thought went into packaging and protecting fragile parts. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:12:18 So the first part that I turned my attention to was the slide. It was not identified in the kit to what size it was before ordering it. I looked at the plating quality first. Much better than the one that came in the carb. Besides a few dents and dings, I found two protrusions, or a mass of either plating material or slide material. There is one on each side. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:13:00 other side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:16:35 Not sure if it matters, since the two slides are not both #7's... it is obvious the cutouts are different angles. I need to measure to find out what size the new one is. I also need to find out which size I should be sticking with. I was hoping it was another identical to what I already have. *EDIT the new slide from the rebuild kit is a #5.5 |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:20:50 On to the float, which was the main reason for buying the rebuild kit in the first place. I figure the heavy slide was bashing the float all the way from where ever it was originally made. It is bent, and will require some gentle straightening. The floats themselves are made from a different type of plastic, but appear to be in much better shape. I haven't tested it in a fuel bath yet. That test will have to wait until after the holiday. Both sides look smoother and better than the cracked one. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:21:17 bottom side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:35:58 Lastly, the new jet selection from Jets-R-Us. I went with three sizes of each. Main - 150, 148, 145 low/idle jet - 40, 38, 35 If testing shows I need to go outside this selection, I will just buy new sizes at that time. I am happy to say all of the new jets are clearly marked, unlike the ones that came in the carb. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:47:31 The last part in the rebuild kit I wanted to compare was the idle screw. The one in the carb had flashing on the tip from the mold process. The new one in the kit has the same flashing, but smaller. The taper is the functional feature, but I will still trim it off for principle if nothing else. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/24/21 at 13:49:01 0B0D027E7C7B7F4F0 wrote:
I finally won something!!! ;D ;D ;D |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 12/25/21 at 05:02:24 6B6D621E1C1B1F2F0 wrote:
I figured it was obvious (especially considering the experience you and Sneeze have) but I guess I missed where that was established. Good to know they work well. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 12/25/21 at 05:03:37 657A5F58525B57445D360 wrote:
I finally won something!!! ;D ;D ;D [/quote]--------------- Yep you got the ugly duckling of the bunch!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/29/21 at 15:25:40 Been so cold out I couldn't keep the shop door open. So I had to switch bikes on the lift to work on something that doesn't run. I put the motor back in to install the chain, just so I can start the mid control mounts. Not much clearance at the swing arm pivot, but it should work out okay. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/29/21 at 15:26:20 close up |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 12/29/21 at 15:27:21 I got this tank for free - much better condition than the tank that came on the bike. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:32:03 I started to design my mid mount foot controls. I have read many threads from guys on here that have done it, and from mid mount to rear mount, they are all different. I picked up an extra set of battery box mount brackets with the intent of following along someone else's idea of straightening them and bolting them to the outside of the frame. I decided I didn't want to do that (being lazy I guess), and mocked up a way to use them in their original shape. I will get extended length hardware and back those bolts with lock nuts to hold them in place. I used the natural saddle feature in the bend to weld a round tube to them. This is just the first mock up. It may change. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:32:42 Used a spacer to control the width at the frame mount. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:33:25 looking down from the seat area |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:35:13 The tube ended up a little close to the swing arm, and the brake linkage tab is blocked. The swing arm won't move much more downward, and the brake linkage will have to be redesigned anyway. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:36:20 I am still planning to use the stock muffler mount bracket (for now). |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:38:21 left side protrusion |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:39:09 right side protrusion |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:41:48 left side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 16:43:17 Plates will be welded to the ends of the tube, which will hold the foot pegs and control pivots. Next up is to design the shape of those plates. Here is previous shot of the foot pegs after bead blasting. |
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Title: Re: 1986 Savage Street Tracker build Post by badwolf on 01/01/22 at 17:25:10 Sure looks like the chain is gonna hit the mount when the shocks compress. And slap it while you ride, under power the top of the chain is tight, and the bottom jumps up and down,,,, alot. When you back off and weight shifts to the front the chain will slap on top of the swingarm. Think about a piece of teflon or nylon on top of the swingarm to quiet it down. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 21:19:25 I am hoping the tube is close enough to the countershaft sprocket to avoid contact. We will see. The majority of the chain travel on the bottom is at the mid point between the two sprockets. The closer to either sprocket, the less the travel. You may be right, but there is limited room to fab in a foot peg mount. I will make it fit without hitting one way or the other! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/01/22 at 21:39:06 I was already thinking about a wrap around the top of the swing arm for chain protection. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 01/02/22 at 04:31:44 You should remove your shocks and conduct a swing study of the swing arm so you understand the dynamics both loaded and unloaded. You just need to place a jack under the engine. |
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Title: Re: 1986 Savage Street Tracker build Post by badwolf on 01/02/22 at 06:24:34 You have a motor mount bolt just behind your kickstand to work with. And I drilled and tapped a 8mm threaded hole in the end of the swingarm pivot bolt for a step,(with all my luggage I can't swing my leg over it), you could do the same and have 2 solid mounts for the left peg. It's your project, do what you want, but the chain slapping while you ride would be annoying. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 08:16:51 I appreciate all the input. As I mentioned, this is just a mock up, and the first one at that. I was planning on cycling the suspension - I was going to compress the rear suspension using ratchet tie downs with the shocks in place. If I remove the shocks I won't know where they bottom out in the swing arm travel. I would like to see where the swing arm stops when there is no more shock travel. Another option for more room would be to change the tubing to .75" od x .12" wall. That would buy an additional .125" on top and on the bottom. This is all experimentation at this point. Final welding will happen only after all issues are dealt with. Tacks are easily cut. |
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Title: Re: 1986 Savage Street Tracker build Post by Gary_in_NJ on 01/02/22 at 10:52:53 You don’t need/want the shocks in place to do a swing survey. You have two data points to work with; the length of the shock fully extended and it’s known travel. Use the jack to place the bike at a height of the fully extended shock. Then use an analog for the shock in the fully compressed position. I use a tie down strap. Lift the wheel and attach the tie down hooks, one to the upper shock mount and one to the lower. Done. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 11:25:17 Just compressing the shocks with the tie downs told the story. You guys were right, the chain will hit under full compression. That natural position in the bend of the brackets was just a bit too convenient. I will start looking at some of the other ideas/options. The whole reason to just tack things and check them out thoroughly before going hog wild and welding it all up on the bench... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 11:25:47 closer view |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 12:52:26 With the chain conversion there isn't much room between the frame and the chain to add plates on the outside using the battery mount bracket bolt locations. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 12:55:51 Another option would be to tie the round tube into the stock muffler support bracket. I could slit the tube to move it rearward off the frame rail. I could also tie/brace the tube with plates that tie into the rear lower motor mounts. I really don't want to make individual/different peg mounts for each side. It would make it harder to keep the two sides symmetrical imho. |
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Title: Re: 1986 Savage Street Tracker build Post by badwolf on 01/02/22 at 14:33:27 You have the one motor mount bolt to work with. If you don't want to mess with the swingarm pivot bolt, you can weld a lug onto the rear of the curve of the frame. Those two spots will give you plenty of support. Some guys shy away from welding on the frame, but you already moved your kickstand,,,,,,so,,,,welding a lug should be a piece of cake. The muffler support bracket would need to be braced alot, it is not made to carry the weight of a rider standing on the pegs. Whatever you do, test it by jumping up and down on each peg before ever riding it. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 15:24:52 Welding some tabs to the frame is definitely on the table. This bike will never go back to a stock restoration. Tying into the lower rear motor mount and another tab welded to the frame is the best solution for support while keeping the entire foot control mount underneath the chain. The entire frame and swing arm will be stripped and powder coated anyway. Right now I am playing with cardboard and a scissors. I want this to end up looking clean when finished, not cobbled together like a hack with a $50 MIG welder from a garage sale. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/02/22 at 15:43:12 Duplicating the tab on the right side, that is used to mount the muffler brace bracket, on the left side sounds like a good starting point. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 01/02/22 at 18:39:13 I did mine with the stock shocks and belt. It was still a tight fit. But it can be done. RYCAs bracket worked with longer shocks and they offered a modified version to work with chain conversions. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/04/22 at 15:13:14 I haven't been successful in finding a good picture of the RYCA foot control bracket. I would definitely like to see how they were doing it. |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 01/05/22 at 16:27:27 I pretty much copied theirs except for the center bar (I had planned on putting a removable crossmember there but never got around to it or needed it) and I shaped the ears on mine a little different to work with the pegs I had. http://suzukisavage.com/yabb2.2/Attachments/Rearset.jpg |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 01/05/22 at 16:33:06 nerdsport did a cool build and did his own take on a RYCA bracket. He used the factory pedals on his but I think he might have had a high pipe. EDIT: LOL, both of those pictures were contained in this thread (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1530551600/3). http://suzukisavage.com/yabb2.2/Attachments/savage_controls.JPG |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/05/22 at 16:40:06 I am not a fan of the dirt bike pegs. I would rather use some rubber ones to cut down on the foot buzz. I have some .120" thick cold roll steel coming to start cutting brackets. Doing a lot of playing with cardboard right now for ideas and shapes. Deep in the deign phase... but it may take a few more cold ones before I settle on something. 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/05/22 at 21:28:14 Oh, looky, looky!!! I finally scored the exhaust I was looking for. It showed up today. An unused Mac Performance exhaust. All of the clamps and bracketry came with it. Another piece of the puzzle. As soon as the piston comes in, the top end machine work will commence. This baby's gonna breathe! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/07/22 at 14:00:43 Mocking up the exhaust position to make sure the foot peg mount doesn't want to be in the same place. The mount will utilize the lower rear motor mount and the exhaust mount bracket tab on the right side, and I will weld a tab on the left in the same position. Two frame mount positions on each side of the foot peg mounting assembly. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/07/22 at 14:04:00 2522232527253E254A0 wrote:
Thanks, Ohiomoto. Not the easiest forum to search in. I have logged more failed searches than successful ones on here! |
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Title: Re: 1986 Savage Street Tracker build Post by ohiomoto on 01/08/22 at 06:34:53 This one has more detailed pictures. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1487785879/0 There have been a few people who have used under frame mount peg mounts like these: http://https://i.ebayimg.com/thumbs/images/g/NFEAAOSw9mtd2Hcf/s-l300.jpg Whatever you come up with please add it to the DYI mid-control thread for other to see. |
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Title: Re: 1986 Savage Street Tracker build Post by Edub on 01/08/22 at 11:36:49 Just read all 26 pages of your extraordinary work, TheSneeze! Subscribed and looking forward to following your build with interest. Love the fabrication and your thorough documentation, hopefully this one will get added to the build thread sticky. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/08/22 at 18:01:55 Thanks, Edub! By your log on name you wouldn't happen to be into VW's, would you? |
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Title: Re: 1986 Savage Street Tracker build Post by Edub on 01/08/22 at 22:36:13 I love VW’s , but haven’t owned one in many years. I grew up around them, bus, squareback, and my last one, a Super Beetle. Keep thinking I’d like to get another, but my focus is primarily on bikes these days. The signature is actually a reference to my initials, EW. Strangely, I’d never thought about the VW connection, thanks for pointing it out! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/09/22 at 06:23:37 I have been into bugs all my life. I built this one 15 years ago, and still going strong! |
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Title: Re: 1986 Savage Street Tracker build Post by Edub on 01/09/22 at 09:11:39 Sweet!!! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/09/22 at 13:16:31 So far my mind has led me to use a 2" x 1/8" angle to span from left to right, using these "inner" brackets to bolt to the lower rear engine mount, and a tab for the top hole. The tab already exists on the right side for the exhaust support bracket. The end of the angle will be capped off with another plate that the foot pegs will mount to, as well as the control pivots. The length of the angle will control foot peg distance left to right. Outer plates not designed yet. One step at a time. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/09/22 at 13:35:32 Preliminary outer bracket. This foot peg position would put the end to end width of the pegs at around 24". |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 10:31:55 By utilizing this light weight cardboard I should save several pounds. I just have to remember not to ride in the rain. :o |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 14:19:22 I got my tab in the mail today. These were the closest size I could find to match the factory tab on the right side of the frame. A little trimming, weld a nut to it, and it should duplicate the position on the opposite side. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 14:19:50 nut side |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 14:20:51 Frame view of right side tab with exhaust support bracket removed. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 14:21:29 new tab position mimicking the other side. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 14:31:54 Here's a tip for all you hobby welders out there. One of the best ways to improve your weld quality - clean all the surfaces in the HAZ (heat affected zone) prior to welding! I see so many welds where the metal wasn't cleaned properly prior to welding. So many think "the weld will melt through anyway". Particularly rust - which is iron oxide. Oxide = oxygen. The reason all welding is done under a bath of inert gasses - to remove all oxygen from the weld flame area. Oxygen is bad for molten metal. Don't get lazy and not properly prep the area. You can see in this pic that the new tab has been scoured on a wire wheel, even though it was received unpainted or unplated. You really can't get your parts clean enough. And whatever you do, don't weld over ANY type of plating. Especially zinc plating - clear or gold colored. When it melts it releases fumes that are VERY unhealthy. Always clean your parts down to bare steel. Even the edges. All surfaces in the HAZ. And whatever you do, DO NOT USE BRAKE CLEANER on parts to be welded. Brake cleaners have some nasty stuff in it, and it leaves a clear chemical film. When this is atomized in the flame, the fumes CAN KILL. (putting soap box away...) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/10/22 at 15:43:09 I have always preferred to practice the K.I.S.S. principle. Keep It Simple Stupid. An easy way to help fixture the tab for measuring. A steel rod that fits close with the thread ID will help keep things symmetrical. The tab will get tacked in place, then the alignment marks will be cleaned off prior to final welding. |
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Title: Re: 1986 Savage Street Tracker build Post by Edub on 01/10/22 at 21:59:55 Great tip using the rod like that, thanks for sharing! |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/17/22 at 12:10:16 I have been traveling for the last week, so not much progress. But it's time to get after the cylinder head. After masking off the stems I set about bead blasting the carbon off. After a nice cleaning with 80 grit glass bead, they look like they are in good shape. I have to get the ends ground at the engine shop, but other than that I think a relap in the seats should do the trick instead of having the seats reground. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/17/22 at 12:17:50 I am hoping the ends can be ground to a minimum clean up and still be within spec. The two intake valves are showing the most pitting. It isn't very expensive to have the ends ground, so I will measure them after the end clean up and see if any have to be replaced. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/17/22 at 12:18:38 the rear ones from the last pic |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/17/22 at 14:22:10 I just got back from dropping the head off at the machine shop. He will use the stock valves if he can, if not Kibblewhite valves a new guides will be installed. I am having him do the porting for me. I provided all the measurements and sketches that DragBikeMike posted on his hotrod thread. As soon as the 94mm flat top piston arrives (should be soon) he will hone the cylinder to match the piston, and gap the rings. Sounds like I need to get my mid controls finished soon as the motor will be getting all the attention pretty quickly. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/17/22 at 15:34:33 Bonanza. Those valves are hard to come by. You have reduced diameter stems. I have a set of those in a head I bought off eBay. You have a 1986 model; do I have that correct? The newer valves don't incorporate that feature. The intake port flowed 4% better and aside from the port being a bit cleaner, the valves were the only significant difference that I could perceive. I have no idea how thick the case-hardened shell is. Does your machine shop have some rule of thumb they use for resurfacing the tips? You will be running the Mac header so you can take that exhaust port all the way out to 1.79". |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/17/22 at 15:56:17 After I started my thread, I found out by deciphering the VIN that this bike is an '87, not an '86. Doesn't make much difference, though. Not sure if the Kibblewhite valves are available, or needed yet. He will measure everything and let me know. If we can use the originals, that will be the preference to keep costs down. This shop specializes in single cylinder four stroke engines - mainly dirt bikes. But he has more experience porting heads than I do. That translates into better odds of success than me trying it for the first time. The head will get blasted, then ultrasonic cleaned. Should be purdy when done. To resurface the ends of the valves you have to stay within the factory length tolerance. This is measured from the end of the valve to the nearest edge of the spring keeper groove. It was an obscure mention in the FSM, but I found it. No overall length was provided in the FSM. The stem length is listed in the service specifications at .110", with no tolerance listed. Section 3-28 of the FSM lists this as the minimum length before replacing the valve. So we will see if the stem diameters are within spec first, then do a minimum clean up grind and see if the required length is still there. If Kibblewhite valves are not available, and they need replacing, stock replacements will be used. I will get the 30 degree back cut done as well. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/19/22 at 09:36:03 I found out the local engine machine shop that I have used has closed its doors last August. Bummer. After much searching, I found the nearest machine shop with the ability to grind valve stems is 45 miles away. Time for a half day road trip! I think my truck will consume more gas than the grinding will cost. Big plus - the guy will do the job while I wait. Time to find out if they will clean up within spec... |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/19/22 at 14:28:15 All four cleaned up well within the specification. They are back with the engine shop. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/19/22 at 14:29:07 This is for DragBikeMike (can't attach pics in PM's) |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/19/22 at 15:37:17 Just ordered my Superbrace for the front forks. With Tkat out of the picture there wasn't much choice. Not running without one. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:16:07 Background: Sneezy received a #5.5 slide in his overhaul kit. It had some defects in the chrome plating. I bought a kit to evaluate, and it had the correct #7.0 slide. It was also in better condition. We swapped the slides. When he tried to insert the new 7.0 slide in his carb, it sticks half-way in. Sneezy, thanks for the sketch. If you look in the bore of your carb you should see a significant gap between the slide and carb bore (as shown in this pic approx .09"). |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:17:12 That gap is on my 36mm PWK with your #5.5 slide installed. I did a rough measurement on the bore in way of the slide and it’s .77”. I used an inside caliper. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:18:15 Check your bore and make sure it’s around .77”. I’m pretty sure it will be around .77”. If it is you can ignore the .698/.699 dimension shown on your sketch. This picture shows the clearance between my 7.0 slide and the outlet side of the slide bore (the large arc). You can see light coming through. There is ample clearance. I realize there is a support pad for the slide that runs up & down the center of the bore, but at the bottom, close to the venturi, it’s a full arc. So there must be ample clearance down there to permit light to get through. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:18:52 This is your #5.5 slide in the same carb body. You can see there is more light getting through, indicating a larger gap. You should be able use a feeler gage to survey the whole arc across the outlet side. That might uncover some blemish that is causing the bind. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:19:41 The two dimensions you should be concerned with are the width (nominally 1.600”) and dimension “A” shown on this markup. I measured “A” at .446” on my #7.0 and .435” on your #5.5. I never measured the #7.0 slide I sent to you (except for the cutaway). The width on your old #5.5 slide is 1.596” and the width on the #7.0 is 1.607”. There are big variations in dimensions. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:20:24 I measured dimension “A” using a surface plate, 123 blocks, and a dial indicator. I set the zero reference using my known-good #7.0 slide. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:21:05 The #5,5 slide you sent me read -.011”. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:21:52 Then I stacked a .375 tool bit and some feeler gages to return the indicator to zero. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:22:25 And double checked the stack with a micrometer. So, I know the #7.0 is .446”and the #5.5 is .435” (.446 - .011 = .435). The #7.0 works fine in my PWK36 and also my pseudo PWK40. Your old #5.5 also goes in & out of my PWK36 just fine. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 13:23:45 Here’s a suggestion that might help you determine where the bind is. Clean your slide with a good solvent and then apply a very light coat of flat-black primer. Let the primer dry and then carefully insert the slide into the carb body. The primer should rub away wherever the slide makes hard contact. Let us know what you find. Looks like your valve stem tips came out sweet. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 13:42:53 Of all my tools, measuring equipment I am sorely short of. Funny as I ran a QA lab at the metal fab shop for 24 years. The slide is binding across the entire length of the large radius. Not gap or light at all. I will try to set up your measurement as accurately as my tools allow and let you know what I find. This is the "I'm stuck!" position. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 13:43:49 "light" view with sunlight backing. No visible light traces. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 13:57:17 First I zero'ed my drop indicator on the flat bar. Yes, the sheet metal was cleaned under the flat bar, and no burrs on the flat bar either. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 13:58:10 Here is the apex measurement of the nice plating DBM #7 slide. .445" |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 14:01:42 Here is the apex measurement of the crappy plating #7 slide that came with the carb (it slides up and down smoothly). .440" My only conclusion is the .005" difference in thickness is what causes the bind. I took some 340 grit sand paper to the support "runner" in the carb, but it will take a much more aggressive grit paper to remove even .003-.004" of metal. What I did really had no affect. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 14:07:26 Here you can just make out a shiny rub mark in the center of the support rib where I had sanded. There are no visible marks on the slide surfaces. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/20/22 at 16:35:57 I would stay away from that downstream side of the carb body (the arced side). If you want to remove metal, take it off the upstream side, the two straight sections adjacent to the bore. Does your bore have that large gap as shown in my picture (the .09" gap, reply #402)? You have some options. 1. Use the ugly slide. It goes up & down. It has a #7.0 cutaway. Just cause its ugly doesn't mean it won't work. 2. Lap the carb body with a slide. Use coarse grit to speed metal removal. Only apply the lapping compound to the flat runners on the upstream side of the slide. If you have no interest in using the ugly slide, and want to preserve the good 7.0 slide, use the ugly slide for a lapping tool. I don't think you have much to remove. It shouldn't take too much effort. Your investment is low, so your risk is low. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/20/22 at 20:35:53 I am going to go with option #1. I have taken some very fine sandpaper and knocked the top of the plating "pimples" off, just to make sure it is not acting like a file so much on the inside of the carb. Let me know what you find out with that #5.5 slide. It will be interesting (as always) to read your findings. |
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Title: Re: 1986 Savage Street Tracker build Post by DragBikeMike on 01/21/22 at 08:15:43 "Let me know what you find out with that #5.5 slide." Of course. Let us know how you do with the lapping. BTW, based on the back & forth so far, it seems like that 7.0 I sent you is a good slide. Correct cutaway, half-decent plating, dimensions seem correct (.445 x 1.600). I got that slide in a cheap overhaul kit (about $15 bucks). The kit is from an outfit called "Nicheflag". Looks like they are in the lawnmower business. I intend to do a report on the kit, similar to the one I did on the "All About Carbs" kit. Where did you get your kit from? Who makes it? Here's the packaging for the Nicheflag kit. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/21/22 at 09:54:30 I bought the rebuild kit off Fleabay, from a seller called Autocparts. The kit was in an unmarked carboard box (small). |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/21/22 at 09:55:41 The engine shop doing my cylinder and head may end up cutting new valve seats. Still yet to be evaluated. We will see. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/21/22 at 12:35:30 I finally found my DR650 clutch parts. It took some scrounging, and keeping an eye out for parts in decent shape. As soon as those arrive, I will have a batch of stuff going to a machine shop for features I can't do here. Enlarge pressure plate center hole Cut spring seats in actuator plate Mill side cover for starter gear mod |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/21/22 at 12:44:01 The first step in my mid controls is in place. Now to finish the end plate templates and start cutting some metal. The inner end plates that will mount here will need a spacer on the back side as the motor mount bung and the tabs are not in the same plane. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/22/22 at 16:48:45 All of the brackets in the next few images are still in development, and more than likely will change shape. So, that being said, here is the latest mock up of my "under the chain" mid controls. Nothing will be coming from the frame between the upper and lower path of the chain. That is the design goal. Material thicknesses are subject to design change as well. Two "inner" plates will attach the assembly to the frame via the rear lower motor mount bolt and the tabs off the frame, and will be joined together by a length of 2" angle running across the width of the frame. The "outer" plates that hold the shifter pivot and foot peg assembly will weld to the end of the protruding angle. A clearance hole will be required to access the rear frame mount bolt (added tab). Everything is still very much a rough design at this point. I have not gotten to the right side, or the brake pedal pivot yet. One side at a time here, folks. I will jump off that bridge when this side is finished. This is the inner mount plate template and 2" angle. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/22/22 at 16:50:15 Outer mount plate in approximate position |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/22/22 at 16:53:05 The inner mount plate will have to be clearanced to be able to remove the shift lever (after the mid control assembly is off the bike). |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/22/22 at 16:55:46 Here is where the foot peg will end up. The shift lever will be between 5.25" and 5.50" centerline to centerline of the foot peg location. I have some Tarrozi rear sets on a Kawi, and the shift lever is at 5" on those. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/22/22 at 16:59:56 This outer plate I cut from 11 ga. steel. I think with the leverage of standing on the pegs the upper part of the plate will flex downward and bend. I am leaning toward moving up to 3/16" thick plate instead of the 11 ga. (.120"). The inner mount plate will end up the same thickness. No, I am not concerned about weight as this bike is already considerably light than the stock configuration, and the motor is getting all of DMB's hot rod mods. The kickstand will clear everything, even though it looks like an interference in the pics. Retracted position on this stand is adjustable as well. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/22/22 at 17:02:02 All of that being said, I welcome friendly opinions and criticism. This whole approach is a design in flux at this point. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 14:21:31 Once again I am waiting on material to arrive before I can continue on the mid controls. So I started to mess around with my new adjustable fork caps. The first thing I noticed about these caps is the flat washer that rests on top of the spring spacer. It was too close to the spacer tube diameter for my comfort. Under higher preloads the flat washer could push into the spacer tube. After measuring, The spacer tube OD was about 1.25" with a wall thickness of .023". Really thin wall! The flat washer measured at 1.22" in diameter. This wasn't going to work. Using the spacer tube as a guide, I traced a circle onto some sheet, and used the marker as a guide to grind back the metal. I left a little marker intact to ensure the new washer was in fact bigger than the spacer. I only had 16 ga., and the original washer was 14 ga. Concerned about the new washer bending, I decided to use both - the larger in contact with the spacer tube. I made a countersink in the original washer to gain enough space for the cotter pin to still fit. Now there is added strength and the washer can't push into the spacer tube. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 14:22:12 Washer is slightly smaller than the tube OD |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 14:23:25 Added countersink to gain room for the extra washer under the cotter pin |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 14:23:49 doubled up |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 14:24:24 Now I can sleep at night! ;D |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 14:25:59 The trick with this modification was to get the new washer bigger than the spacer OD, but smaller than the threads on the inside of the fork tube, so the washer movement wouldn't damage the threads when adding preload. 8-) |
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Title: Re: 1986 Savage Street Tracker build Post by Edub on 01/23/22 at 15:38:16 Nice work, TheSneeze! How long did that little headache take to fix? |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 16:14:01 A couple hours fiddling around, test fitting, grinding some more... it's just shop time to me. It's my happy place. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/23/22 at 16:51:27 This is with the adjusters at the lowest preload setting. |
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Title: Re: 1986 Savage Street Tracker build Post by Edub on 01/24/22 at 05:33:26 302F0A0D070E021108630 wrote:
Totally understand, it’s my happy place too, when I have the opportunity to make things. Doesn’t happen enough in my garage, though. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/24/22 at 13:40:06 I got my used DR650 clutch basket in the post today. After seeing comparison pictures of the LS hub and DR hub next to each other, I assumed the baskets would be a different height to accommodate the extra plates. I am wrong in thinking this? One of things I hate buying off of Fleabay - how do you know you got the right part? Here are comparison photos of what is supposed to be a 1993 DR650 clutch basket next to the stock 1987 LS one. LS is on the left, DR on the right in all three of these pictures. Appears to be the same height. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/24/22 at 13:41:02 top view. The DR unit clearly has more rivets. |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 01/24/22 at 13:42:46 bottom view. No springs. So can any of you that have done this clutch mod ease my worried mind? Is it only the DR hub that is taller and the baskets are the same height for both models? |
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Title: Re: 1987 Savage Street Tracker build Post by badwolf on 01/24/22 at 16:11:32 Are you SURE this is a direct swap? The oil pump drive gear is way smaller, and does not look like it will swap. ??? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/24/22 at 16:21:26 1) I am not sure I got what I ordered. 2) After re-reading the beef up the clutch thread, I may have misunderstood that the DR clutch basket was needed as well. I may have paid for a part I don't need. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 01/24/22 at 18:43:27 Yes, you paid for a part you didn’t need. You only need the hub. The pressure disc is nice to have but you can bore out the LS pressure disc to suit the DR hub. See my reply to your post on the beefed up clutch for info on the pressure disc machining. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/25/22 at 07:43:37 Isn't the first time I have wasted money on something I couldn't use for this project, and more than likely won't be the last, either. Oh well. You have to break a few eggs to make a nice omelet. I am heading out to the machine shop today to modify more parts. I am interested in finding out the cost. I will post the info when I get the quote. Side cover - remove material and deepen shaft hole for wider starter gear Clutch actuator plate - deepen spring seats Clutch pressure plate - open hole for DR650 hub clearance |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/25/22 at 11:05:01 Out of the three parts to modify, the side cover is the most complicated, set up wise. The machine shop labor rate is $95/hr. He estimated at least an hour of set up alone on the side cover. That being said, he told me all the parts should be under 3 hours labor, so less than $300. We will see where the labor ends up in a few days. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 01/25/22 at 14:09:12 Have your side panels printed. Do you have a CAD program? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/25/22 at 15:28:20 Side panels? I do not have any CAD program. I had a copy of MasterCAM from my working days, but apparently the program decided to retire when I did. I can no longer get it to work. I loved drawing stuff in that program too... |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/27/22 at 13:27:22 So the modification of the side cover (starter torque eliminator gear), the clutch actuation plate (spring seats), and the clutch pressure plate (larger hole for the DR hub) ended up at $200 labor for machining. I am totally fine with that. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/27/22 at 15:34:41 Always love getting parts in the mail. I got my DR650 clutch hub today. I also picked up the engine parts from the machine shop. This is the new to me (used) hub. Very little wear, the marks from the disc tabs are hardly noticeable when you run your fingers over them. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/27/22 at 15:36:00 The pressure plate hole diameter came out great. Fits nice and smooth with a little bit of play. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/27/22 at 15:40:43 The actuator plate for the clutch looks good too, but it needs a bit of deburr work. I never would let any customer parts with burrs leave my shop, but this is light work and really no big deal. I went with a diameter of .875" and lowered the spring seats .040". |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/27/22 at 15:44:41 Now I need the material to show up so I can continue on my mid mount foot controls. My new piston is on the way, so once all the top end is back from the engine shop I should be ready to start cleaning and reassembling the engine. After I complete the mid controls I will be ready for a major powder coat run - frame, triple clamps, swing arm, seat/tail support frame, and the front fork sliders. |
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Title: Re: 1987 Savage Street Tracker build Post by zipidachimp on 01/28/22 at 01:15:02 Sneeze: with all this work you're doing, I thought I'd ask what the temp is in your shop? I've taken Dec and Jan off cause it's too darn cold in my shop (35F) . Cheers! 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/28/22 at 07:49:57 I have a well insulated shop. 6" walls, insulated roll up doors, and the ceiling is insulated as well. Lately it has been in the teens in the morning here (12 today), but the coldest I have seen inside the shop is 46. With my wood burning stove it takes around an hour to an hour and a half to bring it up to 68 degrees. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 01/28/22 at 22:22:45 796643444E474B58412A0 wrote:
Nice stove! Very cool. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/29/22 at 13:01:05 My 94 mm flat top piston arrived today! Thanks, Lancer!! |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 01/29/22 at 13:37:08 That's a sweet lookin combustion chamber. What's the volume (in ccs)? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/29/22 at 13:45:46 Just under 24,000 cc |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/30/22 at 09:58:22 I received more parts, so of course, more pictures! I mentioned already that the Lancer piston arrived. It showed up in a velvet bag, which is fitting since this thing looks like jewelry!!! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/30/22 at 10:00:28 I also received my Superbrace fork brace. Also a very nice piece! I haven't figured out what the four phillips pan head screws are for yet. Anyone know first hand? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/30/22 at 10:02:28 The flat bar steel also showed up. 3/16" x 4 cold rolled steel. Today I will be cutting foot control brackets. I found one of my timing chain guides was bent. Not sure how that happened, but had to address it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/30/22 at 10:03:34 A little pressure while supporting it in the vise and it straightened up nicely. |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 01/30/22 at 19:05:46 What's important to be aware of on the guides is the plastic. We had 1 report of the plastic coming off the spine and clogging the oil pump. Don't remember him doing anything to the guide, but straightening and numerous cracks would be cause for concern. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/30/22 at 19:08:37 I was pretty gentle with it, and it didn't have to move much to get the arc back in it. I will check it carefully under magnification and look for any cracks. If I see any I will replace it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/31/22 at 11:46:52 As of this morning, all of the top end parts are at the engine builder's shop. He told me he is 3 - 4 weeks for completion of the job (valve seats, head porting, cylinder hone, ring gapping). I was hoping to have the motor back together by the end of February, but now it is looking more like March. I will have all the powder coating done before I get the motor parts back. Yesterday I started making thicker mount plates for my mid controls. By utilizing the stock muffler support bracket, it complicated the right side. These pics ore the initial shape - not final yet. They still may change. I have scrapped the idea to join the two frame mount plates using a 2" angle. Still chewing on it, but I am leaning on not joining the right and left sides into one assembly and keep them as separate bolt on units. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/31/22 at 11:50:30 As you can see on the right side, the muffler support bracket really gets in the way of everything. One of the main reasons I mat keep each side as a separate bolt on assembly instead of joining them across the middle of the bike. I am still trying to figure out the brake pedal pivot position and the linkage to the rear wheel. And how to keep the foot pegs symmetrical. Yeah, that too... :o |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 01/31/22 at 15:18:59 Not sure what the final plan is but make sure you get your pegs high enough for safe cornering. My pegs are above the stock pipe and shift shaft. http://suzukisavage.com/yabb2.2/Attachments/IMG_20170326_155514279.jpg http://suzukisavage.com/yabb2.2/Attachments/IMG_20170326_152216287.jpg |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/31/22 at 15:45:56 I am still working out the outer mount plate that holds the pegs. I was taking note of your set up, and where the upper bolt was in relation to the swing arm pivot. Do you happen to know the distance from the outside of your pegs, side to side? My KZ750 with Tarozzi rear sets is about 24". These may end up closer to 25". The outer plate shape and position is still being worked out. There will be two spacer tubes welded between the inner and outer plates. Not sure if the left and right assemblies will be joined across the middle yet. But so far the template looks like this. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/31/22 at 16:23:07 Did you trim the countershaft pulley cover to follow the lines of the foot peg? The rear edge appears to be at a different angle. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 01/31/22 at 18:13:33 I see where you are going. That makes more sense now. One concern I would have is the top of the plate possibly pulling out from the leverage of the peg. Maybe a peg that has a straight mount like our rear pegs would work well with that style mount to reduce the leverage? Or possibly tie the tops together to keep those forces in check (if needed)? Not being critical of your work. Just thinking out loud here. Yes, I did trim the cover on the belt. I was just trying to keep everything tight to the bike. Also, my shift lever is a little short so the pull is a little heavy. Not so heavy I can't ride in tennis shoes, just takes a firm pull for upshifts. I might keep the linkage if/when I do my next project. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/31/22 at 18:22:12 Due to the added leverage from the lower mounts I am making the plates from .188" cold rolled flat bar. It will be rigid enough. The lower chain run is in the way, so an additional gusset as high as I can get it may be added. This whole thing is still in a state of flux, and changing every time I look at it! Even the inner mount plates may be remade. This is why they call it custom design work. Never just right the first time through. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 01/31/22 at 18:26:57 What centerline distance between your foot peg and shifter? Same with your brake pedal. I am using (or going to try) the stock brake pedal if I can. My peg to shifter is planned 5.5" - which is the spacing on my rear sets on my KZ. |
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Title: Re: 1986 Savage Street Tracker build Post by Dave on 02/01/22 at 04:36:55 0C1336313B323E2D345F0 wrote:
Well it only took me a month to reply to this. I just counted the teeth on a 5 speed engine. Crankshaft drive gear 37, Clutch Basket 67 Your 4 speed bike has a 0.5294 ratio.....the 5 speed is 0.5522 ratio. The change is a 4.3% higher drive for the 5 speed. If you want to trade one of your 4 speed gear sets for a 5 speed.....I am willing to trade with you. |
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Title: Re: 1987 Savage Street Tracker build Post by Dan P on 02/01/22 at 06:58:11 Ohiomoto, do you recall what bike you sourced out your brake pedal from ? Thank you |
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Title: Re: 1986 Savage Street Tracker build Post by TheSneeze on 02/01/22 at 08:04:57 53686572636F747269616C73000 wrote:
If you want to trade one of your 4 speed gear sets for a 5 speed.....I am willing to trade with you. [/quote] Is the 5 speed gear set a straight swap into a 4 speed early case? I had assumed that wouldn't work, so I didn't consider pursuing it. I have two sets of transmissions (actually two full bottom ends). Since my bike has less than 10k miles on it I was considering leaving the bottom end sealed. Do you know of anyone who has swapped the transmission gear sets? |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 02/01/22 at 09:23:46 I don't know if anyone has ever made the swap. I assumed that they would interchange - as I thought that only the early 4 speed bikes had the 36/68....and later 4 speed bikes had the 37/67. I will go look on a parts list and see what I can find out. I know the cases and transmissions won't swap, as the 5 speed has an extra shaft and slider for the additional gear. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/01/22 at 09:50:49 If it isn't a straight swap it doesn't make much sense to me as I would need to find a later model case. That would more than likely end up being a used motor, which would include the transmission. I am too far into this early engine to switch paths (clutch upgrade, starter torque gear mod, etc.). If you need an early four speed transmission we may be able to work out some other mutually beneficial arrangement. |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 02/01/22 at 11:33:50 I don't think you can swap a 4spd tranny into a 5spd case or vice versa. I know 1 person complained when they tried replacing a final drive shaft and it didn't fit. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 02/01/22 at 11:38:34 342730312E2325272C73420 wrote:
It is not the intent to swap a 4 speed transmission for a 5 speed one. The question is can you swap the 35/65 primary gears for the 37/67 primary gears - or vice versa. There may be little or no reason to do so - as it is easier to change sprockets on thie Street Tracker build. But it is a question I have wondered for a while. Owners of 4 speed bikes could make the change to get a 4% higher gearing......owners of 5 speed bikes could reduce their gearing byk 4%. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 02/01/22 at 12:33:34 05262D26032629470 wrote:
XS400 More info can be found here: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1487785879/0 |
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Title: Re: 1987 Savage Street Tracker build Post by Dan P on 02/02/22 at 09:00:02 Thank you ! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/02/22 at 15:02:06 With the spacers welded on the inside of the inner mount plates, I started to measure for the spacers to join the outer plates to them. After considering the force being applied to the outer plates by the foot pegs, I decided that trying to go without a spacer running across between the inner plates would be a mistake. This spacer tube will help prevent the bottom of the inner plates trying to flex inward. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/02/22 at 15:08:01 Now comes a critical part - the four spacer tubes holding the inner and outer mount plates together. I really wish I had a lathe in my shop so I could guarantee the ends of the spacers were parallel and square. These parts will determine how far out the foot pegs end up side to side, and also the position front to back. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 02/02/22 at 17:48:12 I like the direction you're going. Once you get it worked out be sure to add it to the DYI mid control thread. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 02/02/22 at 18:05:05 4641404644465D46290 wrote:
Sounds like Yoda. "Do Yourself It" :-? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/02/22 at 19:55:14 I think this will end up being a viable solution for the chain conversion crowd. Not enough room for the bracket around the swing arm with the chain there. So far I am happy where this is going. More cutting, grinding, and welding tomorrow. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 02/03/22 at 10:10:57 Oops! Good catch Dave. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/03/22 at 16:31:38 A lot of fitting, grinding and welding today. It took me a while, tacking, fitting, cutting tacks, retacking, fitting, etc. But I finally am happy with the fit of what I am calling the "lower cradle". Eagle eyes will spot two different size spacers on the inside of the side plates. It's not easy getting a new tab to land in the exact same spot as the factory one on the opposite side. Yeah, some of my welds aren't pretty either. But as I tell my wife, I may not be pretty at it, but I get good penetration! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/03/22 at 16:31:59 side shot |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/03/22 at 16:37:14 I spent a lot of time making the outer mounting plates symmetrical. The third hole is a clearance hole for one of the frame bolts. No other way to get the bolt in after the outer mount plates are welded on. I haven't added the clearance hole in the other plate yet. There is some addition material removal on the top edges that needs addressing as well. Like I said, lots of grinding and fitting! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/04/22 at 11:47:15 My neighbor's son dropped by this morning. Turns out he bought a used '03 DR650! It was fun checking out his bike as I have never looked at one up close. Then I told him about the DR650 parts I am putting in my Savage. Brought him into my shop to show off the change and progress. He had no idea some early DR parts could be used on another model. The LS/DR crowd sure is a small world! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/05/22 at 16:08:48 The right side decided to throw a wrench in my design plan gears. This approach may not be viable after all. The one main thing I learned today is I have to have the exhaust in place first. Time to set the mid controls aside as I won't have the cylinder and head back for another 3 weeks or so. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/18/22 at 11:46:07 I started to check out all of the electrical for my bike as it came with the bike in a box. Unknown condition. Looking at the FSM on how to check components and (to me) the instructions are vague at best. Using an ohm meter, it says to check continuity between the wires per the chart on the combination gage (speedo). If the continuity measured is incorrect, replace the components. Nowhere does it say what the continuity should read! I guess I have to assume there should be little to no resistance between the listed connections? What am I missing here? |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 02/18/22 at 12:18:03 Continuity is just that. Set the meter to infinity and listen for the "beep". If it beeps, there's continuity. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/21/22 at 13:25:41 After scrapping my foot peg mount design on the right side I had a shop pow wow with Dan P over where our builds are going with the foot controls. I just ended up pulling the trigger on a set of universal Tarozzi rearsets from Cafe Racer Web Shop. I know this is not a cafe build, but I can adapt them to the bike in the position I want much easier. Yeah, they are more money, but they look great in my opinion. Folding, rubber coated, and indexable (a big plus). |
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Title: Re: 1987 Savage Street Tracker build Post by Dan P on 02/21/22 at 13:55:38 Thumbs up ! |
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Title: Re: 1987 Savage Street Tracker build Post by badwolf on 02/21/22 at 15:50:14 Are you going to use a rod for the rear brake? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/21/22 at 16:08:21 I haven't gotten there yet. But probably. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 02/21/22 at 17:07:14 My experience with a rear brake rod was. Stainless is nice - 1/4" is too thin and flexes too much if you need to put in some bends, and when you step on the brake pedal you get a lot of rod bending and very little brake action. I used 5/16" and for the bends I had it works fine....it actually gives you a bit better control as the flex gives you a brake action that is progressive and not easy to lock up. I had to cut the end of the rod down in my lathe to allow it to be threaded to 6mm for the adjustment nut. It is really important to get the die started straight when you are threading for several inches, as the die will go farther off center the longer the threads you cut. I also used a rear brake lever from a Suzuki Boulevard C50 that had a rear lever without the offset bend - the rear of the lever where the rod mount does not go outward like it does on the Savage. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/21/22 at 17:21:20 Good info, Dave! Thanks. |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 02/21/22 at 17:57:19 Too bad a DR head won’t fit on our LS. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 02/21/22 at 21:08:53 Those are some mighty sweet lookin controls. I think they will look good on your tracker. |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 02/22/22 at 22:45:00 I had to do some repair work on RYCA rear sets. I believe the indexing pin is too small and was elongating the index holes. I made a slightly larger pin to remove the wobbliness. but probably needs to be a lot larger. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/23/22 at 07:42:43 These are Tarozzi rearsets, and I already have a set of these on my '81 KZ750. Very good quality, and haven't had any issue with the indexing pin. I will post up some detailed pics of them when they arrive (shipping from the Netherlands). Having the single mounting point at the peg centerline will greatly simplify the mounting plate design, which is why I went ahead with these. The control arms on these are black, the ones on my KZ look identical, only silver. Since my Savage will have the frame powder coated silver I plan to swap out the control arms. My KZ motor is blacked out, so these will look better on it, and the silver ones will go better with the silver Savage frame. Just another benefit that pushed me over on the purchase. For those who are curious, total shipped cost on these was $162 and change. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/23/22 at 07:47:49 4449464B4D5A1A1F280 wrote:
But the DR cam bolts right in! |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 02/23/22 at 08:02:10 4E51747379707C6F761D0 wrote:
But the DR cam bolts right in![/quote] Yep, same base core. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/23/22 at 21:09:48 I got the battery and charger in the mail today. Man, this this is small! Only 1.5 lbs as well. Time to start to mount for the regulator/rectifier and the battery! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 02/23/22 at 21:10:43 It is smaller than the carburetor! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/01/22 at 10:59:01 I came home from a weekend trip to find a pleasant surprise on my front porch. I ordered these Tarozzi universal rear sets from Caferacerwebshop.com based in the Netherlands on 2-21, and they arrive in only one week. These will simplify the mounting issues I have run into. You can tell by the pics that Tarozzi makes a high quality product. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/01/22 at 10:59:54 Another view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/01/22 at 11:00:18 Exploded view parts list |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 03/01/22 at 11:15:30 Be sure to use blue locktite on final assembly (dont ask how I know). Even those nyloc nuts will loosen from the vibration produced from this giant thumper. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 03/01/22 at 13:52:02 3D373339323B3F36686E6A5A0 wrote:
Yep.....same with my bike. The bolts holding the pegs on loosened in a very short amount of riding. Anymore I use the blue threadlocker on all the chassis bolts except axles and bolts that hold the engine together. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/01/22 at 14:41:15 Yes, copious amounts of Loctite will be used during final assembly. This will be a frame up build after it gets powder coated. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/03/22 at 15:24:04 I was messing around with my PWK carb today. After going through DragBikeMike's carburetor thread I noticed another difference on my carb from his - the float vent tubes are not there. His carb has a brass nipples smaller than the inlet nipple. My PWK knock off |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/03/22 at 15:26:06 DragBikeMike's PWK knock off |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 03/05/22 at 16:12:13 The absence of the top vent connections shouldn't make any difference in the way the carb performs, but IMO the install won't be as neat & tidy. The top connections allow the vent hoses to be run straight up into the frame, similar to the stock carb. You have had a number of issues with your PWK (slide, float, vent connections). Can you take a screen shot of the vendor you purchased from and post it as a jpeg file. Who did you buy it from? I've purchased three of these things. The first was a 38mm air striker that I got from DCMotive. Spammy is a member of this forum. That PWK was ace in every respect. All it needed was a different slide needle and smaller main and pilot jets. It ran perfect. The second was a 40mm standard PWK I got from JFG racing. It also is ace in every respect. I've been running it for a long time and it is flawless. Same deal, new needle and smaller jets. Never, ever needs adjustment. Great fuel economy. Superb throttle response. The third was a 36mm standard PWK I got from JFG Racing. Again, stellar running carb. A bit too small for my taste but it ran excellent. I just used it for a comparison test to see how a 36mm would perform. The photos you have posted show me that your PWK will most likely run just fine now that you have the bugs ironed out, but I would be reluctant to purchase from the same vendor. It's tricky. As I recall, Duderino said he bought his from JFG racing, but his came with a removable needle jet (IMO a nice feature). He had some difficulty getting it set up. I believe his last post reported that he had it running good. Who did you get your PWK from? Was it an Amazon purchase? Is there a link I can go to? I would like to see their add. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/05/22 at 16:17:04 I got it off of FleaBay. I posted the seller earlier in this thread. Probably not a good decision. At the cost, I am seriously considering buying another from a more reputable source. Seller was blackhary7 |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/06/22 at 14:20:13 Yesterday I got the piece of metal I needed to keep moving forward on my mid-controls. 3/16" x 1-1/2" flat bar. As I mentioned earlier, the Tarozzi rear sets greatly simplified the foot peg mount design. I have ruthlessly murdered a bunch of cardboard, and some metal bits as well. Cardboard is cheap! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/06/22 at 14:21:22 The width will help hide the bracket behind the foot peg assembly. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/06/22 at 14:22:56 The bottom of the mount plate still needs to be shaped to size before welding. I am still playing around with the exact peg position as well. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/06/22 at 14:23:47 another view. I will still need to wait for my cylinder/head/piston to be finished at the engine shop before I can work on the right side mount. The exhaust pipe needs to be fully mounted so I can be sure of the necessary clearance. The right side will not be symmetrical because of the pipe. This will make it more challenging to get the pegs in the same spot. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 03/06/22 at 15:15:02 That’s gonna work well. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/08/22 at 18:27:23 I managed to figure out where the pipe was gonna live, and realized what I suspected. The right side mount plate was too short to clear the exhaust. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/08/22 at 18:30:12 So I ended up cutting apart the lower assembly to weld in a taller end plate. That ended up with a new tube to save the left end plate. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/08/22 at 18:32:29 The brake lever clears the engine case well. Now the foot control mounts will clear the exhaust pipe. I will set up a fixture on the bench to locate the pegs symmetrically for welding. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/08/22 at 18:33:09 another view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/09/22 at 15:10:34 More goodies showed up today. I got some PJ1 Fast Black engine and case paint in advance of the motor going together. I finally heard from the engine shop, so the top end should be back in a week or so. I had real good luck with this paint on my KZ750 motor, so I'm going to use it on the tracker motor. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/09/22 at 15:12:50 I also ordered some plastic sheet for the inner rear fender. I am using some 1/8" x 6" UHMW (ultra high molecular weight) for it's impact resistant properties. That should help with the road debris from the rear wheel. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/09/22 at 15:13:37 It will be trimmed down some in length, but the 6" width is perfect. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/09/22 at 15:23:33 I also got my multi-tool from my laser guy. I used the files that were posted on the thread. Holds the clutch, the flywheel, and also for the steering stem nut. You can read about it here: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1603670561/0 |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 03/10/22 at 09:25:19 That tool is amazing, thanks for posting the link! I’m sure it’ll help a lot of people who missed the original thread. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/13/22 at 14:26:08 I made the end plates of the frame mount flat for two reasons - I didn't want them hanging lower then the frame, and it makes it easier to set up on the weld table and get measurements the same on each side. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/13/22 at 14:27:35 I always save metal drops from project for this very reason - cobbing together fixtures! A nice way to ensure the foot pegs are in line in all axis. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/13/22 at 14:28:15 With the pegs in place |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 14:03:18 Design attempt #3. Getting ready for tack welding the entire assembly together for the first time. Once cooled off, the first test fit with the pegs in position will happen. If that passes muster, it will be disassembled for final welding. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 15:07:47 The test fit passes inspection! My bike has mid controls for the first time! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 15:08:39 View from the front |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 15:09:12 Exhaust clearance is good |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 15:10:05 Brake lever to case clearance |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 15:11:49 The "X" on the case represents where the foot peg center line was going to be using the XS400 pegs I started with. The design morphed as I went, and it resulted in around a 2" shift rearward. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 16:56:31 The whole assembly comes of in one piece (after the exhaust is removed). |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/14/22 at 16:58:02 Here is the final weldment (prior to cleaning). It took me three tries to get to this. But I am definitely happy with results. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 03/14/22 at 17:28:23 Looks good! |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 03/14/22 at 18:56:36 The peg location looks to be very similar to where they are on my Cafe' bike with the RYCA mounts. The laces on my work boots can get sucked into the slots in the pulley cover and the belt can destroy them in a millisecond! ;) |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 03/14/22 at 22:52:44 5E41646369606C7F660D0 wrote:
Looks amazing! Any possibility of you making a .DWG or .DXF template for the assembly? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/15/22 at 07:57:03 I don't have the software to do that. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 03/15/22 at 20:19:36 Great work! I have the software, but haven’t had a chance to fabricate a set of rear sets. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/18/22 at 08:57:22 6B505D4A5B574C4A5159544B380 wrote:
Maybe a stainless steel screen JB welded to the inside of the sprocket cover over the slots would prevent lace murder. It would look kinda cool, too. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/18/22 at 09:06:42 Today I am making a trip to the engine builder's shop. I want to go over his progress on the porting work, the stud below the exhaust port was too stubborn to come out. He had to cut it off and drill it out, so I am supplying a new stud for installation after the head is resurfaced. I am hoping to have the head and cylinder back in my shop by next weekend. I am still working on cleaning up the mid mount weldment. Areas where more material can be removed, getting rid of more weld berries, etc. Once I am happy with that process, it will go in the blast cabinet for a complete spray down. I am getting very close to a complete strip down to the frame so I can complete the dress down of bracket remnants and the like. I have also decided to tear down my rebuilt forks so the sliders can get powder coated along with the frame and swing arm. I may have to replace the new seals I put in, but it will be worth it. The age is showing on the clear coat on the sliders. After seeing Dan P's powder coated sliders on some of his other bikes I had to go the same route. If he is okay with me doing it, I will post up some pictures of his restoration collection. This guy does some really amazing work! |
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Title: Re: 1987 Savage Street Tracker build Post by Dan P on 03/18/22 at 10:23:51 Thank you Steve (Sneeze) for the compliments Appreciate it ! Go ahead a post away. Dan P |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 03/18/22 at 11:20:55 091633343E373B28315A0 wrote:
Maybe a stainless steel screen JB welded to the inside of the sprocket cover over the slots would prevent lace murder. It would look kinda cool, too.[/quote] You might have trouble with that, a number of people have had clearance issues with the inside of the cover and pulley. |
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Title: Re: 1987 Savage Street Tracker build Post by Theduderino on 03/19/22 at 03:03:50 Its a daily battle lol… yes mine has removable needle jet. Gonna open the carb today( needle adj) shes runnin just rich on the high side of the throttle. But she is fun! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/21/22 at 15:15:21 But wait! There's more!!! Now new and improved with gussets. After standing on the pegs, I could notice a small amount of flex in the 3/16" thick end plates. So, after 30 minutes of messing about, the fix is in. My 200 lb self could jump on these babies now! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 03/21/22 at 22:56:55 That setup is looking STOUT now! Well done. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/23/22 at 09:14:53 After reading on here about the cheap LED lights, and charging up my new battery, I decided to test the tail/brake/turn lights on the unit I bought. You guys are correct, it just isn't bright enough in daylight to be seen by other motorists. I guess I bought it based on looks for the most part. So I switched directions and ordered up a new tail/brake light that uses an incandescent bulb. If this one isn't bright enough, I will look into replacing the bulb with something brighter. That means I am back to having to come up with turn signals. For the headlight I will be putting a 7" bucket up front using a bracket that bolts to the two holes in the stock lower triple clamp (thanks, Dave!). |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/23/22 at 12:28:58 Quote:
I think with the chain conversion there is a little added room than with the stock belt drive sprocket. Looks like something as thin as a screen could work. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/23/22 at 14:11:29 I found these turn signals after a bit of searching. They are incandescent bulb, and DOT approved. Made by K & S. I will add some weld tabs to my seat frame for the rear mounting. I will need to fab some brackets to mount the fronts. Once I have them in hand, I will see if I can modify or add to the stock clamps to mount them to the fork tubes. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/24/22 at 17:23:18 Oh happy day! I got the call from the engine builder - my top end is ready! I am picking it up tomorrow morning, so I will post pics of the work tomorrow afternoon. 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:22:26 I got all of the top end home. We tried to get away with just lapping the valves to see if the seal could be restored without grinding the valves. I think I may need to take the head and valves in for a regrind. More on that after a few pics. Here is the batch, all sonic cleaned. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:23:17 Top side of the head. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:23:47 Combustion chamber |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:25:03 Intake port |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:25:38 Exhaust port |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:35:05 Here is the areas of concern for me. You can see the "groove" along the valve seat on the head. This is on one of the intake seats. I think it needs to be ground smooth, and the valve relapped after grinding. The shop that did my head and cylinder work does not have valve grinding equipment. I already have another engine shop (45 miles away) that can get this addressed. We were both hoping a good lapping would take care of this, but it didn't. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:36:47 Since the valves need a 30 degree back cut, a regrind will take care of this line on one of the exhaust valves. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:40:08 The cylinder came out really good, with just a hone to size it to the Lancer/Wiseco 94mm flat top HC piston. Piston to cylinder clearance was .0035" |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/25/22 at 13:43:08 I got this bike in a non-running state with the clock showing 9658 miles, but who knows how accurate that really is. So far, I am pleased with how the engine parts are cleaning up with minimal cost and effort. Not that big of a deal about having the valves and seats reground and looking better. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/05/22 at 11:17:30 I am itching to get started on this motor! Unfortunately my schedule is arguing with that plan. Just got home yesterday from a 5 day trip, and I am flying out on Thursday for a 7 day trip. The day after I return we have company staying with us for 3 or 4 days. Oh well... a little here, a little there, and inch forward on this bike. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/19/22 at 15:50:29 Thanks to Dave, my Tracker now has a headlight! Just another one of the parts that I did not get with the incomplete bike I bought. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/20/22 at 14:24:41 I decided to continue with the lights. I ditched the previous LED tail light I bought and went with a DOT approved incandescent tail light. Since this one didn't have the turn signals incorporated into it, I found some stubby turn signals that are also DOT approved incandescent. The license plate bracket will still require an angled bend to clear the rear tire, but there is a clear light for illuminating it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/20/22 at 14:25:16 angle view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/20/22 at 14:25:52 side view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/20/22 at 14:27:17 The l last light mounting will be the front turn signals. They are identical to the rears, but I need to find some mounting clamps for the fork tube to mount them with. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 04/20/22 at 14:28:16 It looks good. If you plan on attaching a tag to that, it will likely make contact with the wheel. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/20/22 at 14:31:45 Mount plate will be bent at an angle, probably more than 45 degrees from vertical. I have the mount plate, but it needs to be modified to fit with the new tail light. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 04/20/22 at 18:08:34 Just make sure you conduct a survey of the available movement of the swingarm (shocks removed) when you have the plate installed. I bent my plate once...repaired the damage...and then rear tire removed the plate from the bike. I couldn't see how it was making contact with the tire until I did a swingarm study. It comes within a 1/2" of the tail light! My plate is now firmly attached to the back side of my battery box. Not a legal location...but the only place it can go (I'm not using one of those axle bolt contraptions). |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 04/20/22 at 19:03:58 The build is looking good. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/20/22 at 21:26:27 I think I will raise the tail light another 3/8" for tire clearance. It is a little lower than the bracket. I want any tire contact to be with the 1/8" angle iron instead of the tail light housing. I missed it by 3/8". Third time's a charm! |
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Title: Re: 1987 Savage Street Tracker build Post by wheelbender6 on 04/24/22 at 06:01:13 Thanks for this thread. Most of the things you did are beyond my skills, but now I know exactly why, LOL. I do feel like I could do a "cosmetic" tracker conversion after studying this build. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/25/22 at 16:01:14 I don't know about a lot of you guys, but I try to use what I have on hand as much as possible in my builds. Be it raw material, or other parts that can be modified to work (and look decent). After reading all of the pros and cons with LED lighting, I went with DOT approved turn signals and tail light. The rear end I had to make all the mount points for these. The front posed a different challenge. I liked the look of the stock turn signal fork clamps. So I thought I would try and go about modifying one to see if it would work with the new turn signals I bought. First was identifying the thread pitch on the new units. M10 x 1.25 threads. The next idea was to try and find an insert that would work in the hole in the stock fork clamp. Before I got very far, I needed to see how the stock stem fit in the clamp. Then I realized if I took all that rubber off of the stock stem, I may be able to use the metal part that fastens to the stock clamp. After removing the rubber, this is what was left. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/25/22 at 16:05:21 The inside diameter turned out just slightly smaller than the drill size for an M10 x 1.25 thread. The drill size is 11/32". After drilling out the ID and tapping the full length, it looks like this. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/25/22 at 16:05:59 Here is how all the parts look prior to assembly. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/25/22 at 16:08:45 And here is the assembled result. Both the stock fork clamp and the modified insert will be powder coated. The short knurled shank protruding from the clamp looks fine to me. Once powder coated, it will blend with the clamp. With a little bit of labor I am able to reuse the stock front turn signal mounts with the aftermarket signals I bought. 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/25/22 at 16:11:53 Yes, I realize I will no longer have the damping characteristics of the rubber stem. I'm running with it anyway... ;D |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 04/25/22 at 23:06:31 Improvise, adapt, overcome! That’s what my USMC drill instructor used to tell us all the time, worked well for you here. Looking forward to your continuing story, this is such a great project. Thanks for taking us along for the ride! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/03/22 at 10:25:23 My first go at thermoforming plastic. Using 1/8" thick ABS plastic sheet I set about making a seat pan. Interesting process, and my results weren't what I set out to achieve. Some waviness in the large radius bend. It won't be visible until you take the seat off the tail piece once it's finished. I am going to be working with Tuffsides to do the upholstery on this seat. Straight pleats in black leather, with blue stitching to accent the Royal blue bodywork. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/03/22 at 10:26:48 This seat pan will bolt to the fiberglass seat/tail section. Still need to add the threaded studs to it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/03/22 at 10:29:55 These are the studs I will put in the seat pan to attach it to the fiberglass. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/03/22 at 10:31:38 I picked up this two part adhesive to bond the studs in place. It will be under the stud heads and also over the top of them. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/03/22 at 21:41:25 Just found another savage near me for $40! Parts bike, but for that price I will try and snag it tomorrow! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/04/22 at 13:19:31 I now own two Savages! I got another '86 or '87 (need to decode the VIN still). It's been down, missing stuff, broken stuff, etc. It has CA plate with a 1990 tag on it. Edit - this one is an '86. My Tracker is an '87. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 05/04/22 at 19:18:44 Congratulations! How did you find such a great deal? I’m obviously looking in the wrong places. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 05/05/22 at 12:23:35 Whoa!!! What a score. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 15:51:08 I have been doing a lot of tinkering today. I am finishing up my seat pan so I can ship it off to the upholstery shop. I will be using Tuffside for the seat. After scuffing the surface, I covered the stud heads with the JB Weld plastic bond. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 15:52:18 The stud lengths had to be trimmed down to aid in installation, and the holes in the fiberglass had to be oversized a little. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 15:53:52 In trying to gain as much tire clearance in the rear, I raised the tail light 3/8". It looks better being tucked in tighter to the tail section. Kind of reminds me of Darth Vader from the rear! Hahahaha! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 15:56:31 I took the stock belt guard and followed the existing angle to shorten it up. I also started cutting up more cardboard to come up with ideas for the side covers. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 15:58:04 This is about as much as I want to bend the license plate frame up. The rear view is still very readable, but it still only give me 3" of upward tire travel. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 15:58:33 Rear view of license plate |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/07/22 at 16:02:21 The seat pan will ship out early next week. Yesterday morning I finally took the head and valves in to an engine shop with valve grinding capability. Unfortunately his back log is steep right now as racing season is getting ready to start. I am probably looking at 6-8 weeks to get the head back. I still have a long way to go on frame mods, the battery box, side panels, gauges, etc. Chipping away, one step at a time. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/24/22 at 21:39:40 Been a while for an update. Things have been moving slowly due to multiple reasons. The head is in for the valve seats (4-6 weeks out), The seat pan is at the upholstery shop (3-4 weeks out), and continuing to tinker. Almost done with the side cover templates. I had a quick thought of using carbon fiber. For 1/8" thick, 12" x 24", it was close to $500. Yeah, not going that route! I finally painted the cylinder. I really like this paint - PJ1 Semi-gloss engine and case paint in rattle can. I used it on my '81 KZ750 resto-mod. It works good. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/24/22 at 21:47:19 I changed the sprockets out from a 17/43 to a 18/52. No more clearance issues with the chain at the swing arm pivot. My bad. I guess I didn't read enough on some of the posts. I have decided on a paint scheme for this build, but that will have to wait for the reveal. As soon as I get the side cover mounts done I can strip it back to the frame and start to prep it for powder coat. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 05/25/22 at 09:39:45 Thank you for keeping us updated, theSneeze! I really appreciate the time you have taken to document the entire process, this is my favorite thread on here. Thanks again, and I look forward to seeing the next steps! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 09:49:14 Thanks, Edub! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 11:59:10 I cut out my side covers out of metal this morning. The rear edges follow the frame angle. Once I am happy with them I will start to design the mounts to the frame. Once these covers are done, I can sent the bodywork out for paint. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 11:59:52 Other side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 12:12:11 Here is the chain clearance at the swing arm pivot with the new sprockets. Thanks for the tip, Gary_In_NJ! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 12:18:52 Ok, I couldn't resist! I had to throw some quick color (temporary) on the side covers to get a better image in my mind. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 05/25/22 at 15:16:42 Lookin better all the time Sneezy. Hey, since your cylinder is off, could you take some pics of your input shaft and gears. Also, can you give your 4th gear a hard look to see if there’s any pitting. It’s the largest diameter gear on the shaft, left-hand side. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 15:43:45 Will do, DBM. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 15:56:14 Outside of some "shiny" wear marks, there is no visible pits on the fourth gear. Here are the input shaft gears. Same thing, just some "shiny" areas. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 15:57:34 This is the gears on the counterbalance shaft to the crank. Are those what you wanted to see? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 16:18:30 trans gears |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/25/22 at 16:30:22 Yup... |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 05/26/22 at 12:52:19 Thanks for the pics Sneezy. Things look pretty clean in there. Your balancer drive gears have a very nice surface finish. Can you do a good visual inspection of your 4th gear (circled in yellow) and see if you can detect any pitting in the contact surfaces on the teeth. Note, the input gears rotate counter-clockwise when viewed from the left-hand side of the engine, so when you are looking directly down at the gear teeth through the opening in the case the load bearing surface is facing up. On your 1st gear, what is the area circled in white? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/26/22 at 13:48:00 DBM - that white mark appears to be a drip of gasket sealer that was squished into the valley between two teeth. I can't get anything down in there to scrape at it other than a long phillips screwdriver. Yes, I used a JIS since it has a pointier tip. I could not disturb it at all. There are no other instances of this on any other gear surfaces. The fourth gear teeth have the same usual wear pattern, but no visible pitting that I can see. This bike (supposedly) had 9800 on the clock when I got it. The bottom end looks good enough that I was going to leave it alone. I also have another spare motor (condition unknown) that I can do exploratory surgery on and rebuild if necessary if this bottom end doesn't like that added power in the top end. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 05/27/22 at 14:31:57 Thanks Sneezy. Good info to have. I appreciate the pics and you doing the visual. Best regards, Mike BTW, clutch release cam holding up good. Action smooth. No drift on adjustment. It’s a keeper. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/27/22 at 15:27:32 All dressed up and no way to weld... found all the pressure had leaked out of my weld gas bottle. Had to run into town for a new bottle. A big thanks to Dan P for the flat pattern for his battery box design. I had it all ready to weld up before I found the bottle empty. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/27/22 at 15:28:03 bottom view - it uses the frame mounts on the bottom, with a new strip welded to the frame for the top. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/27/22 at 15:30:26 I made a couple of brackets for the hold down strap that will be welded on the sides. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/27/22 at 17:08:21 I have a couple holes that still need filling, but it's coming out nice for welding thin sheet metal. The material is 18 gage steel paintlock (pre-primered). Battery is tucked up out of view with the side covers on, just the front corner of the box can be seen. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/27/22 at 17:11:14 Support strap is welded in. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/28/22 at 12:32:45 Filled the minor holes (I hate welding thin sheet metal!), added the brackets for the battery strap, and dressed it down. Ready for blasting and powder coat! I need to address the chain guard mounts now. After I have those welded to the swing arm (shouldn't have cut the brackets off...) it will be time to tear this beast back down to the frame. The to-do list prior to sending all the parts to powder coat is growing smaller! Fork sliders, triple clamps, front turn signal mounts, frame, swing arm, seat sub frame, battery box, mid control bracket, and muffler support bracket will all be metallic silver. Oh yeah... gage mount. I better get off my butt and get the gages coming so I can make that, too. ::) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/28/22 at 12:37:13 The battery is sitting on a 3/16" thick sheet of Buna rubber. It is also lining the sides. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/28/22 at 14:00:13 Stubby chain guard is in da house! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/02/22 at 14:05:45 Everything got dropped off for powder coating today. Kind of a milestone! Once I get all that back, the slow process of putting it all back together will begin. I could be a month out on the head, though. Just a couple weeks on the seat upholstery. Bodywork is not ready for paint yet. I made my side panels out 18 ga. steel, and I think I may use them for templates and go with 1/8" aluminum. I think they would look better being a little thicker. But now is the time to start my benchtop engine stand. There is a lot of cleaning needing to be done on the engine, and the cases will be painted as well. Covers will remain aluminum. As Wizzy is so fond of saying, carry on!! ;D |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/03/22 at 12:09:18 I decided on a DC Motive Speedo/tach combo. I'm going to run this in front of the handlebars and cover the hole in the tank. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/07/22 at 13:14:31 Another milestone on my tracker build. Turning a corner, where things start to go back together instead of being torn down. I can already see the image of the completed bike in my mind! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/07/22 at 13:15:18 More stuff! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/08/22 at 00:40:43 Congratulations! What a great milestone! Looking forward to seeing things going back together!!! |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 06/08/22 at 11:07:55 Where does that DC Motive instrument mount? Does it go in the tank nacelle or will it be mounted on the top tree? I'm lovin that powder coating. Did you get that done locally or did you have to send the parts away? Mind if I ask what the powder coating costs? That tracker is gonna look really good. Very professional build. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/08/22 at 12:08:17 I am going to mount the gage in front of the handlebars. DC Motive makes a mount for it, but the hole spacing is 40 mm, and the hole in the stock lower triple (which I am using as a top) is only 30 mm. I am thinking of making a bracket to go between the two, because I really like SpammyToo's gage mount. The powder coater I used is local to Carson City, about a 30 minute drive from my house. With all the masking labor, burning off the existing paint, sand blasting, etc. he charged me $533 for the lot - 13 different parts. I was estimating between $500-600 when I dropped them off. I wasn't far off the mark. I have dealt with a lot of powder coating in my working career. This same shop did my KZ750 as well - frame, wheels, swing arm, asssociated brackets, etc in three different colors. They do really good work. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/08/22 at 12:11:20 For the curious, here is my KZ750 that I finished before starting on the tracker. It is a resto-mod tribute to the '80's superbikes, using the ELR Racing theme. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/08/22 at 16:44:54 Here are all the parts that were powder coated, unwrapped. I'm really happy with the results. I don't recall ever seeing a Savage with a silver frame, but then my experience with these bikes is very limited. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/08/22 at 21:19:47 716E4B4C464F435049220 wrote:
Okay, these screws are for some plastic fork guards. I am not sure if they are standard Suzuki equipment, and if they are, what year they are from. Any input would help. I want to add them to this build, but I cannot find them anywhere. I tried several years through Partzilla, Google, Ebay, etc. Any sage wisdom out there? |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 06/09/22 at 06:55:17 697653545E575B48513A0 wrote:
Okay, these screws are for some plastic fork guards. I am not sure if they are standard Suzuki equipment, and if they are, what year they are from. Any input would help. I want to add them to this build, but I cannot find them anywhere. I tried several years through Partzilla, Google, Ebay, etc. Any sage wisdom out there?[/quote] Latter model savages have plastic fork guards, but they snap on the lowers and won't transfer. I vaguely remember those use a tin piece that does the same thing. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/09/22 at 15:28:02 New bearings are trickling in. Swing arm bearings showed up today. Still waiting on the new sealing washers for the bottom fork bolts, and the steering head bearings before I can assemble the front end and get the wheels back on. |
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Title: Re: 1987 Savage Street Tracker build Post by zipidachimp on 06/09/22 at 19:27:01 Really nice work. Have you ever considered welding in a couple of flat bars to eliminate the dip between the tank and the rear frame horns? Seat height would rise by about 2". Cheers! 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/09/22 at 19:40:38 Seat height? I think that is already addressed. The seat padding will be 1-1/2" thick. The seat is at the upholstery shop being done. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/09/22 at 19:42:17 It doesn't need any more support. |
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Title: Re: 1987 Savage Street Tracker build Post by zipidachimp on 06/09/22 at 20:23:23 missed that: the seat pan frame does the same thing, cool! Cheers! 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/10/22 at 11:30:38 Since the powder coat came back, I am now focusing on the bodywork so I can get that out to paint. I originally made the side panels out of 18 ga. steel (.045" thick). Once I had them on the bike, I realized it doesn't look right. So I ordered some 1/8" aluminum sheet to remake them. Every custom bike build has parts that are 2nd, 3rd, or even 4th generation. This build is not different. Once I get these thicker aluminum panels made, I plan on putting a 45 degree chamfer around some edges with a router. These should look much better. After the side panels are dialed in I need to take the tank back off and deal with the rust inside. The rust isn't bad, and this is not my first go around taking rust out of a fuel tank. My Green Monster had a very serious rust problem inside, so this one should be a piece of cake. But I need to finish all the work with caustic chemicals before it goes out for paint. The only thing going in this tank after paint will be fuel as to not risk the paint job. The tank cover (speedometer hole) will need to be fabricated as well, but I will more than likely leave it bare aluminum to compliment the silver frame. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 06/10/22 at 15:14:26 Looking good! I actually like the look of that side panel. Sort of artsy. Almost looks like a fan with a helmet and goggles on it. ;) I love the silver frame. I had an old Triumph that had a silver frame. It was cool. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/10/22 at 17:15:54 Thanks! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 11:17:14 Sneak peek! Tuff Sides finished my seat and I should get it sometime next week! Can't wait to see it on the bike! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/11/22 at 12:03:46 687752555F565A49503B0 wrote:
Wow, that’s beautiful! I’m familiar with Tuffside, but haven’t needed one (yet). What do they charge for a custom seat like that? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 16:56:13 Since I made the seat pan and shipped it to him, he charged $250 to upholster it to my sketch/dimensions. It is more if he has to make your seat pan. Now to see the full visual, I have to get the body work painted. Sharp eyes will pick up on the hint... 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 16:58:34 The width of the pleats I left to his discretion. He added a nice touch by increasing the each pleat width as it nears the tank. Top notch work! Tracking says I will be thrilled beyond measure on Wednesday. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/11/22 at 17:48:08 726D484F454C40534A210 wrote:
That’s an excellent shade, looking forward to seeing the paint! Beautiful seat, I hope it’s reasonably comfortable! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 18:12:40 Never having ridden a thumper before, I guess I will find out. At this point, it's all about the build. From what I have read on this forum these are not bikes suited to a long ride. I have some amazing roads here being only 30 minutes from Lake Tahoe. But being retired, I will see how much buzz I can handle. The smallest number of four stroke cylinders in one bike that I have owned was a '70's Honda SL350 twin. Other than that, it has all been in-line 4 cylinder sport bikes. This Savage I bought because it had a '05 Honda CBR600RR front end on it that I wanted. From the steering stem rearward I didn't care about. That modern front end was worth more than I paid for the whole bike, and I got the stock front end with the purchase. I considered this a free Savage. It sat in the corner of my shop collecting dust for a couple years. Then I saw some street trackers online. Those looked really cool to me! When I finally stumbled onto some RYCA pics of the Savage I was hooked. Then I found this forum. The rest, well, is turning into a really long winded build thread! So glad everyone is so helpful on here, you all are really great motorcycle peeps. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 18:17:29 BTW - the thinnest section of padding is 1-1/2" thick. So yeah, we will see how comfortable it ends up. In my mind, street trackers are about style, not comfort. Obviously a cruiser seat on this bike would look, well, like an abomination. :o |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 06/11/22 at 19:05:13 I'm lovin your shop Sneezy. The bike too. But that shop, Nirvana. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 06/11/22 at 19:20:06 302F0A0D070E021108630 wrote:
Of course, it's going to be blue...silver frame and all. :) My 73 TR6 had a silver frame, a deep candy blue, with silver ghost flames. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 20:22:57 Hmmm... what are the Nevada state colors again? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 20:27:43 27212E52505753630 wrote:
DBM - when we moved up here, I told my wife I have one requirement. I need a shop. Either we buy a house that has one, or I will build one. We ended up with a brand new house built on an acre, so I designed and contracted out a 1000 sq ft shop with a 12' ceiling. Without a doubt it is my happy place. My wife was concerned about the lack of separation in retirement (a valid concern). Not an issue! She gets a quiet house all day, I hang in my shop. Best retirement ever... |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/11/22 at 20:41:42 Shop porn |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/12/22 at 09:26:37 Love your shop! When I lived in Southern Nevada, I did a project at Sand Harbor State Park, so I got the opportunity to visit your neighborhood. Incredible roads and scenery up there! I think you’ll enjoy riding the savage tracker on those roads. The Savage is counterbalanced, so it isn’t quite as vibey as some other big thumpers, but the tracker is set up as a shorter distance rider. I expect you’ll love it on those roads! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/12/22 at 14:41:17 A little more deburr work, and these thicker side panels will be ready for paint. They look much better than the thin steel sheet ones I made, and I was able to use the steel ones for the template to cut these out. Right side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/12/22 at 14:41:45 Left side |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 06/12/22 at 14:47:25 I’m liking it. Are you going to use the original fuel tank? Nows the time to fit a replacement. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/12/22 at 14:51:52 That original tank that is on the bike is what I am going to use. I will make a 1/4" cover panel for the speedo hole in the tank. Already have the template made for it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/12/22 at 14:58:07 Only two things left to do before I can go to paint. Fit the seat when it arrives (tracking says Thursday), and de-rust the tank. I use the product Evapo-Rust. Environmentally safe, human contact safe, and works really well. It calls for a water rinse, but my experience with it flash rusting while drying lead me to rinse it with denatured alcohol instead. |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 06/12/22 at 16:27:45 I like the panels; very nice. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 06/12/22 at 16:43:04 Ive had great success with straight while vinegar as a rust remover. Upon draining it is followed with a baking soda/water mix to neutralize the active acid, and then 2-stoke oil to coat the tank. It’s cost effective and the vinegar can be poured into the sink. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/13/22 at 18:27:54 Two gallons of sauce in the tank. Tomorrow I will get an expanding plug for the fill hole, flip it upside down, and take off the seal I made for the petcock hole. Hopefully I will have all the bodywork to paint by the end of the week. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/13/22 at 20:21:10 777D79737871757C222420100 wrote:
Gary, since this tank has to go out for paint, no oil products can be used. It must be clean, rust free, and dry to go to the painters. I got a lot of experience with my kz tank using Evapo-Rust. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/14/22 at 16:26:25 She is officially nekkid for the next month. I dropped off the bodywork at the paint shop this afternoon. The bodywork should arrive about the same time as the cylinder head. Maybe she will fire by the end of summer. Maybe. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 06/14/22 at 16:46:49 I have to say, you have made a lot of progress in a short amount of time. Pretty impressive considering the quality and quantity of work you have done. I wasn't on here for a lot of the earlier builds, but generally speaking, most of us on here would be taking much more time. Maybe being retired and having a nice shop are helping but still, you have to have some gusto to get it done. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/14/22 at 16:52:07 Thanks. I do have my distractions, though. The Kawi took me 2-1/2 years to get where she is now, and not quite done. I committed to shortening that build schedule on this one, you know, three less cylinders and all. But the level of fab work is much higher on this build. And yes, being retired helps! All my working career I dealt with deadlines (like most working stiffs!) and now I find I work much more comfortably knowing that there isn't any. 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 06/14/22 at 16:56:06 Not to get off topic, but check out the Bear Budget Board Tracker build if you haven't already. Pretty impressive how quickly he fabricated that bike. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/14/22 at 17:11:58 I read all the build threads, and styles (including yours) before I started this bike. This is one of the best forums I have had experience with! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/15/22 at 17:59:56 I am a happy man! Except for the part where I put the bodywork in the paint shop yesterday. Should have put that off until the seat showed up. So I had to see how the seat looked just sitting on the support frame. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/15/22 at 18:00:18 top view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/15/22 at 18:00:44 front view |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/15/22 at 19:42:09 That seat looks amazing, TheSneeze! Seems like a great deal given how well made it looks. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/15/22 at 22:14:32 Yeah, I am very happy with the workmanship. As soon as I saw the quality on the seat this guy made for Dan P, I knew I wanted him to do mine. When you hold it in the sun the blue stitching just pops! Really looking forward to the paint work coming back. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/16/22 at 11:50:19 Yeah I wanna see the paint work too. Lookin tight I might add. Where is the seat guy located ? Website or a phone number ? Before I use some 2 way tape and foam , Again ! ;D |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/16/22 at 13:20:49 https://www.tuffside.com/ He is located in southern California. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/16/22 at 13:59:37 So I ran back down to the paint shop just to fetch my seat/tail piece. He isn't starting on the paint for three or more weeks, so I needed to fit check my design and mounting. I have to say Chris at Tough Sides did an amazing job! I love the way the front of the seat follows the lines on the stock tank. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/16/22 at 14:00:40 more pics (everybody loves pics, right?!) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/16/22 at 14:01:20 and the other side |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/16/22 at 18:37:40 Man, that tank has never looked better! The lines of the tank, seat, and tail section are perfect! Well done. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/16/22 at 19:02:48 Thanks! My new steering head bearings came today, and the fork seals yesterday. Now I have what I need to reassemble the forks and the front end. Soon she will be a roller again... |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 06/17/22 at 13:25:02 I agree Edub, all the lines on this thing flow perfectly. Even the angle of the rear shocks compliment the look of the tail section & tank. Looks factory. I’m lovin it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:48:40 I started on my inner rear fender today. Still some fine tuning, but plastic is easy to work with. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:49:17 rear view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:53:09 I had a squirrel moment (happens a lot!), and switched gears. I had to adapt from a 30mm bolt spacing to a 40mm spacing going from the upper triple clamp holes (used to be a stock lower) to the DC Motive gage mount. The mount didn't have as much angle to it that I prefer, so that needed to be dealt with as well. I cut a section out of some 1" x 2" rectangular tubing and started grinding and drilling. This is what it ended up looking like. Just a prototype at this point, but I may use it in the final assembly. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:53:44 side view with increased angle |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:54:19 cockpit view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:54:56 side view in position |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 15:56:23 None of the hardware will be used - these bolts/screws are mock up only. I will use new hardware for final assembly. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/20/22 at 21:33:01 I am thinking about welding in a gusset to fight vibration on the rear opening of this bracket... |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/21/22 at 12:04:40 My wife is starting to think I need an intervention. And here I haven't really gotten started yet! 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 06/21/22 at 17:15:48 Intervention ? Nawwww. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/21/22 at 19:02:19 Lmmfao Someone want to tell him ? You got the the sickness for there is no cure You’ll be sick till it’s finished , then it starts again( next build ) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/21/22 at 21:31:48 I knew there was something I liked about you, Ruttly... now I just need you to explain it to my wife... :o When I told her I want to buy at C5 Z06 Corvette, she said "come back and talk to me when both motorcycles are sold". SAY WHAT???... |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/22/22 at 11:18:36 So sorry already have a wife I answer to. Give you some game , every so often I have to remind her that when I’m in the garage you know where I’m at and what I’m doing , if I’m not in the garage who knows what kind of trouble I can find , bar , booze , drugs , women or drag home some of my friends from low places ! Hence , the garage is a good place to be ! Your Welcome. ;D |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/22/22 at 11:21:30 The Corvette , your on your own Remember only pick the battles you can win ! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/22/22 at 11:38:48 I have a suspicion this tracker is going to end up being too much fun to sell. Just sayin'... |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/22/22 at 14:55:37 Today I decided to start playing around with a cover for that God awful location for the stock speedometer. I really don't know what Suzuki was thinking when they designed the gage location on these bikes. I guess trying to emulate Harleys. After measuring the height of the weld seam around the hole, I picked up a piece of 1/4" thick aluminum. I made a cardboard template of the stock cover first. After transferring it to the aluminum, I placed the template over the weld seams on the tank. Using a deadblow hammer, I tapped all the way around leaving an impression. After trimming the template to the impression, I used it to mark where the groove will be. The lines across the part represented where the direction change needed to be to fit the tank curve. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/22/22 at 14:56:20 Hefty stuff to try to bend! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/22/22 at 14:58:50 When you don't have a full blown press brake with the correct radius tooling, you improvise... (sorry it came out blurry) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/22/22 at 15:02:09 After some minor tweaking of the angle, it fits without much air gap and no rocking. The tricky part comes next. Cutting the groove to get it to sit down on the tank over the weld seams. Probably going to use a dremel with a burr tool. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/24/22 at 16:26:53 Front end Friday! My first look at the silver and black front end. I went with black accents - bars, turn signal brackets, fork brace, and last will be the axle spacers. I may even paint the caliper black as well. Just enough black to accent all that silver! Me likey!! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/28/22 at 11:38:34 I finally did something about mirrors. After acquiring two Savages, and a bunch of parts, I have yet to be able to mount a stock mirror to my tracker. I have one good mirror, but every one of the several mounts are broken in one way or the other. Searching high and low for some decent sized mirrors that wouldn't break the bank proved harder than I thought. Most are only sold as one. I like symmetry, so I wanted a pair. Most quality mirrors start at $80-90 and just go up from there. I found these on Revzilla, and they were only $90 for the pair. I am pleasantly surprised at the quality! All aluminum, black anodized. Hopefully the anodize holds up in the sun. Improperly sealed anodize fads in UV light pretty quickly. A good sign the manufacturer was either cutting corners in the plating process, or just done improperly. Time will tell, but so far I am happy with the look. They even come with adapters for either 7/8" or 1" diameter bars. |
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Title: Re: 1987 Savage Street Tracker build Post by justin_o_guy2 on 06/28/22 at 13:33:30 Nicely pleasing to the eye. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/28/22 at 14:15:22 real world problems. Up, or down? Here is up |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/28/22 at 14:17:13 And here is down. I might try fitting them inside the switch controls/throttle, but I may improve the view of my elbows being that far inward. I will have to sit on it to see where the best visibility is. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/28/22 at 14:27:57 The machining detail on the back looks pretty cool, too! |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 06/28/22 at 15:57:11 Does down contact the tank? I prefer up, this way your eyes aren't diverted too far from the road to look in the mirrors. Down looks cool; up is safer. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 06/28/22 at 17:00:43 Down is so cool...it is not cool and never was cool...especially on a tracker! IMO of course. haha |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/28/22 at 17:57:29 I still need to see how it looks (while sitting on the bike) with the mirrors up and inboard of the handlebar controls. Conventional style. I definitely want the most visibility from them. On a side note - the cylinder head is finished! I got a voicemail today that the valve seats have been refinished. The last major component of the engine is finally coming home. :) |
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Title: Re: 1987 Savage Street Tracker build Post by justin_o_guy2 on 06/29/22 at 09:56:17 I wouldn't decide based on looks. Try a ride on a low traffic road and see how it works with them down. If it takes more time to get eyeballs seeing what you need to see to be safe than the other way, then there is your answer. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/29/22 at 13:05:16 I picked up the cylinder head and valves this morning. With the exception of gaskets and seals, I have everything I need for the motor now. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/29/22 at 13:06:24 I had the seats redone, and included a 30 degree back cut. That's the shiny portion nearest the stem. Every little bit of flow helps. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/29/22 at 16:42:43 The fins on the cylinder head will get the edges sanded clean after full cure on the paint. |
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Title: Re: 1987 Savage Street Tracker build Post by justin_o_guy2 on 06/29/22 at 17:11:01 You lose five points for insufficient clutter. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/29/22 at 18:12:12 Witness my garden, where I grow my F's. See that it is barren, thus no F's left to give... ;D ;D ;D ;) Don't dare me to start showing my clutter, JoG. This thread will stray so far off course it will get lost forever! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 06/29/22 at 19:16:43 I’m partial to the mirrors facing downward, but it’s your bike, man. Love the engine parts, that’s a beautiful porting job! The clutter discussion was priceless, guys. Keep the conversation going! |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 06/30/22 at 10:35:57 Hey Sneezy, howzabout throwin in some more pics of those ports? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/30/22 at 11:05:46 When the masking comes off I will. The head only has one coat on it. I need to put some more paint down first. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/30/22 at 11:09:30 57515E22202723130 wrote:
In the mean time, go to page 38, replies #566 & 567. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/01/22 at 17:24:18 0D0B04787A7D79490 wrote:
Okay, here you go, DBM... I chickened out doing the porting myself, as at the time I only had one head. Didn't want to screw myself making a rookie mistake, and I have never done porting before. In retirement I find my hand control is not what it used to be, either. So I had Built Motors do the porting. I provided all your dimensions and photos, but stopped short of doing any epoxy work. I applaud your innovative approach to port shaping, but that again is a bit over my skill/effort level. So the owner of Built Motors used to work for Thumper Racing here in Gardnerville, NV. Due to multiple back surgeries, he finally closed down his business about two years ago. He did the valve job on my KZ750 motor. Kevin, the owner of Built Motors bought most of Thumper Racing's equipment and started his shop. Having a lot of experience in single four stroke racing motors, he did a mix of what he knows, and the porting details your Hot Rod thread. Enough back story, here is what I have... Exhaust port |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/01/22 at 17:25:16 Exhaust - valve side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/01/22 at 17:26:23 Intake side - a more coarse surface for atomization |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/01/22 at 17:26:56 Intake - valve side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/01/22 at 17:27:31 All dressed up and ready for the party!! |
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Title: Re: 1987 Savage Street Tracker build Post by justin_o_guy2 on 07/02/22 at 00:36:16 That is real pretty ,in every way |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 07/03/22 at 10:43:28 Very nice If your motor was driven by another power source and fuel removed it would be nothing but a air compressor , the more air in the more air out. This is very important, efficiently processing air. Now add your performance carb and exhaust. A great recipe , porting is so important. Especially the exhaust port on a Savage , it needs lots of very careful work. The intake side was very good stock , only needed a little work. Exhaust side is the worst I’ve ever seen on any engine. I’ve seen better shaped exhaust ports on lawnmower engines. Cams are important too but the engine has to efficiently be able to process more air in and more air out ! |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 07/03/22 at 16:26:22 Thanks for the pics Sneezy. I have added them to my library. Sorry, I had forgotten that you had the porting and the valve work done by different shops. I'm sure you will be happy with the performance. As I recall, you are installing a Wiseco Flat-Top. Is that correct? BTW, awhile back you posted some pics of another PWK you ordered. You mentioned you were gonna open up that new carb and check out the innards. Did you ever do that? Is it a keeper? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/03/22 at 17:26:06 Yes, I am going to run a 94mm flat top. Rings are gapped already to the fresh cylinder hone. I have the second PWK, but haven't opened it up yet. Visual and slide operation makes me think this one is a winner. I am currently on another project with a time constraint, so the Savage isn't getting any love at the moment. The paint work is starting by the end of this week, so at least that is moving along. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 07/05/22 at 10:37:14 You're gonna love that piston. Please post some pics of your setup when you do valve-to-piston clearance checks and quench clearance checks. I'm curious how you are gonna do the checks and what your results are. Same goes for the crab inspection. Very interested to see what you find in there. Particulalrly curious about the needle jet. Dudarino got that removable needle jet that required short main jets. Curious what you have. Thanks, Mike |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/05/22 at 13:22:00 DBM - I picked up some modeling clay at the store for the valve to piston clearance. Deck height is easy to measure as I have a mag base and a drop indicator. I have to hunt up that business that makes custom thickness copper gaskets. I was planning to set the deck height by varying the base gasket thickness under the cylinder. All of the 13 plate clutch mods are done and ready for assembly. But... this hot mess has a time limit on it. I have a trip planned in the Mojave desert the last weekend of July. So the front suspension rebuild takes priority at the moment. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 07/05/22 at 17:24:28 Cool az grocery getter |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 07/05/22 at 17:40:21 Looks like a cool bug..gie :) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/06/22 at 11:03:54 Getting the groceries... |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 07/06/22 at 22:19:54 SWEET Baja Bug! Wow! Details please!!! |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 07/06/22 at 22:49:19 The eggs won’t stand a chance ! ;D |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/07/22 at 06:30:40 1970 'vert VW Full tube chassis Subaru EJ25 sohc n/a motor, 220 hp 091 vw bus trans w/ Weddle internals 13" travel f & r Fox coil overs 22 gal. fuel cell suspension seats w/5 pt harnesses Lowrance GPS 6000 lb winch Electric power steering |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 07/07/22 at 08:04:38 YEEHAAAAA !!! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 07/07/22 at 09:30:29 0A1530373D34382B32590 wrote:
Sweet baby Jeebus!!!! That’s cool, man. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/07/22 at 09:42:57 My old license plate in CA started with "5NZE", so my kids called it the Sneeze. Thus, my log in name... |
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Title: Re: 1987 Savage Street Tracker build Post by justin_o_guy2 on 07/08/22 at 07:35:30 You dodged a bullet there, Duude! It coulda been DKHD.. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/27/22 at 14:36:53 She is telling me she's lonely and needs some lovin'... but multiple trips and family visits on the near horizon. Time is in short supply these days. I should get the body work back from the paint shop in the next week or so. I found a graphics shop to do my tank stickers. Not putting them into the paint so if I decide to sell it they won't be permanent. The paint theme will be revealed once I get all of this in my hands. Once the baja suspension is back together the shop will get a major cleaning, and then I can start focusing on the tracker's motor rebuild. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 07/28/22 at 13:08:56 Looking great, TheSneeze! The lines of your bike are just perfect. I look forward to the next update when you have time! |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 07/29/22 at 12:25:44 Very nice job really like supporting framework for seat glass & tail/turn. I may use that design one day rather than a heavy subframe. The tires interest me too. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/14/22 at 07:04:46 I almost had the baja back on the road, which is my road block to get back on the Tracker. Then... Covid. Crap. Anyone who doesn't think this is as serious and as contagious as they say has their head in the sand. Within 3 days the whole house came down with it. It's kicking my tushy. No energy, fever, congestion, cough, you name it. Maybe in another week or so I will be back at it in my shop. Yes, I am vaccinated. Probably the only reason I am not in the hospital right now. Stay safe, and healthy, everyone. Maybe the world will get over this pandemic eventually. :-/ |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/14/22 at 08:51:21 Screw everything , it will wait , Get Well |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 08/15/22 at 22:03:52 425D787F757C70637A110 wrote:
Take care of yourself man. My wife’s highly immunocompromised, so I’ve had to take it deathly seriously form the beginning. Thanks for letting us know, you’ll be in my prayers man. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 08/17/22 at 03:08:14 Sneezy, hope you and your family are feeling better. Get well soon. Respect the Vid. Serious stuff. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 11:27:49 So I finally got some negative test results. Then I got the call from the paint shop! All my bodywork was ready. Such great news to end my quarantine. Took some spare towels to wrap it all up in, and brought the stuff home. As soon as I got to the rear patio, my Labrador jumped under my feet and I went head over tails - while carrying the fresh paint... The tank bounced on the concrete then rolled across it into the grass. The tail piece also hit the concrete. The two side panels were wrapped up enough as to not receive any damage. I have to admit, the thought of shooting my dog crossed my mind. I am hoping the scratches will come out with some rubbing compound. The tank has a dent the size of dime, and a lot of scratching. >:( >:( >:( Once I get it all buffed out, and the graphics on the tank, I will post some reveal shots. Talk about having some emotional highs and lows all at once! No happy campers over here. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 13:01:20 So I couldn't wait to see how the paint looks installed on the frame. I am not putting the graphics on yet, as I want to see what the paint shop will charge to fix the dent. If it will be repaired I don't want to waste the graphics. So here are some preliminary shots (including the damage). |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 13:01:55 right side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 13:02:21 left side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 13:02:43 left side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 13:03:16 The dent! AAAAHHHHHHH!!!! >:( >:( >:( |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 13:07:23 So the theme of my street tracker is a University Of Reno, Nevada (UNR) Wolfpack, after their sports teams. The bike is painted the official state colors - silver and blue. A white wolfpack logo will go on each side of the tank. Here is a back lit shot of the tank graphic. The graphic is 6" x 3" in size. I chose to do a sticker rather than have it in the paint. The main reason was if a future owner didn't want to have the logo. A new reason is the tank may need to be reshot after repairing the dent. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/22/22 at 15:12:10 Looks great , nice touch blue seams on the seat. Dent REALLY SUCKS |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/22/22 at 15:18:46 My language was as blue as the body work. All focused at the dog! For the animal lovers among us, I have been, and always will be a dog person. I know it wasn't done on purpose, and I could never bring myself to shoot a pet. But dayum that hurt... On a side note - I have found as I age, the concrete becomes harder than it was when I was, say, 10 years old. Much, much, harder. Both my knee and elbow will be reminding me about the laws of gravity for the next week or two. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 08/22/22 at 16:53:38 Oh man I woulda been sick. Like right there, on the spot, sit down and cry sick. Oh well, it still looks ultra-sweet. Very nice indeed. Totally professional. I'd leave it. Adds character. Glad you are feelin better. |
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Title: Re: 1987 Savage Street Tracker build Post by SpamyToo on 08/22/22 at 17:41:26 Ive had some dents like that removed from tanks by a "Paintless dent repair specilist". He used special bent rods inside the tank and massaged the dents out. As long as the paint isnt cracked it can then be buffed out. I was really suprised how good they looked afterwards. At that time he charged me $50 a dent. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 08/22/22 at 18:18:55 Love the color scheme. Too bad Labs are so darned friendly! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 08/23/22 at 23:44:05 So happy to hear you’re doing better, Sneeze! Color looks amazing, although isn’t UNR blue a bit darker than that? As a former UNLV faculty member, I remember seeing that color on the cannon when our team finally won the rivalry for once ;D So sorry to hear about the dent, man what a bummer! Hopefully fixing it won’t be too much trouble. I’ve got a big dent in my Yamaha’s tank that I keep postponing dealing with, it’s gonna be a pain! Anyway, happy progress is being made now that you’re feeling better! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/24/22 at 15:02:45 Edub - yes, the UNR logo uses a darker blue. But I went with the Nevada state colors. Not the UNR blue. Yes, the wolfpack logo is going on it. And when you get right down to it, almost every shade of blue has been used with Nevada merchandise. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/25/22 at 03:05:11 Don’t forget about a blue headlight bulb too. Paint , seams on the seat and a blue headlight bulb. Gotta have that blue theme. I think it is a white xenon halogen bulb , has that blue tint , works better than stock , eBay I like mine , I have some blue in the paint job too ! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/25/22 at 06:48:02 Paint job? What paint job? Oohhh... the one you have never posted any pictures of!! Pics or it never happened, pal! |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/25/22 at 13:42:11 Hell , my wife still hasn’t seen it. I work 70 miles from here , I work 6 to 7 days a week , anywhere between 8 (yeah right ) to 12 hours , so with about 3 hours travel time doesn’t leave much time for everything else in life. Besides I suck as a photographer, so use your imagination. I eat peer pressure for breakfast , I never nut up , knuckle under or shiver and piss myself. I revel in peer pressure, what works on everyone else won’t work on me , ask my bosses. So send more , Feed me ;D It’s got a ways to go still |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/25/22 at 14:21:13 ;D ;D ;D |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/25/22 at 20:15:36 We might just finish both bikes very near to one another. It’s always another delay. No need to spend too much money on yours cause mine will be faster. All my R & D has been done it’s about data collection, any tuning will be minor(jet swap). How far are you from say Truckee ? It would be fun to do a track day at a local short track. Ya know bang bars , swap some paint , ride stupid a get black flagged , fun stuff . I don’t know about you but I’m building a daily rider not a show bike. It’s time this bike starts paying me back with some seat time. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/25/22 at 20:43:18 I am about an hour and a half from Truckee, maybe less if I take it through Reno instead of Lake Tahoe. I am just south of Carson City. I would love to do a track day, once this hot rod is broken in. It would be a ton of fun comparing machines and bangin' some bars! Unfortunately I sold off my leathers quite some time ago. I took a 26 year hiatus from two wheels after my first kid was born. Long story, but came close to watching a friend come close to losing his life on a ride with me when the #1 kid was 5 days old. A bit of a game changer. But now I am retired, and just as stupid as I was! So why not! Once the racing is in your blood you never get it out. After two wheels, I got into sports car racing with the SCCA. Figured a roll cage and fenders was better than two wheels. That's me in the #38 passing on the apron at California Speedway. I saw pavement... the stewards saw a little differently! LOL! |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/25/22 at 22:02:04 Ain’t like all 4 tires were on the apron , right ;D I haven’t raced in 34 years, whenever I watch flat track my heart pounds. Ya know we say it’s for fun but it gets real serious real fast with 2 old racers. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/25/22 at 22:29:42 We are going to some local flat track races in Carson City this Saturday. Fun stuff! |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 08/25/22 at 22:44:04 0F10353238313D2E375C0 wrote:
Ooh, RX7!!! I approve!!!! Loved those cars! |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/25/22 at 22:56:51 Lodi Cycle Bowl is half hour away from me , very famous track in these parts. Some racers find it customary to race there night before they race the Sacramento Mile. Blue groove tracks are usually faster than the Cush tracks. I did 2 laps at San Jose mile on a Honda XR200 , wfo 72 mph all the way around , also did a lap on the same bike on knobbies at Laguna Seca. I also attended many races at Laguna Seca,San Jose & Sac miles and lots of local tracks. Lodi is a special place , you would be hard pressed trying to find any famous flat tracker that hasn’t raced there. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/27/22 at 11:31:22 The work on the baja is done and it's on the trail once more. I had to do a major shop clean and rearrange to fit the donor vehicle for another vehicle project I have lined up. So now I have 4 work benches, 3 motorcycles, a baja, and a '04 Dodge Dakota 4 door in my shop. Since I can't move around very much, it's the perfect time to start on the tracker motor. Yay! |
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Title: Re: 1987 Savage Street Tracker build Post by zipidachimp on 08/27/22 at 12:35:43 What's with the RX7 ? Up here, you can't give away an RX8 ! Cheers! 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/27/22 at 13:18:26 I raced in a spec class called Pro-7. I raced from 1996 to 2004 with the California Sports Car Club (SCCA).I ran at California Speedway, Willow Springs, and Buttonwillow raceway. Never made it to Laguna Seca, unfortunately. How to make a million dollars racing? Start with two million dollars... |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/30/22 at 14:13:44 In a "I'm not paying to reshoot this tank" moment, I went ahead and put the graphics on the tank. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/30/22 at 14:14:23 left side |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 08/30/22 at 17:33:32 Love the wolf and your bikes lines. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 09/01/22 at 11:35:12 The nugget finally made it to the cleaning table. Rather odd, since it took quite a while to clean off the cleaning table! First point of order is to get the center case cleaned and paint ready. It will be getting the same paint as the cylinder - semigloss black by PJ1. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 09/01/22 at 11:35:45 side 2 |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 09/29/22 at 07:44:14 I needed to get my other bike onto my lift for some work, so I put the kick stand on the tracker and rolled it off the lift. One thing I found out that no one mentioned - when you use the stock lower triple clamp as an upper to allow ride height adjustability, and use the stock tank, the triple clamp will hit the tank before the steering stops make contact. This probably is not an issue with the shortened Ryca tank. Luckily I discovered the interference without damaging my tank or paint job. Another thing to address. First thought was to add welds to the stop to build them up, but everything is already powder coated. |
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Title: Re: 1987 Savage Street Tracker build Post by justin_o_guy2 on 09/29/22 at 08:05:19 Can you cut aluminum, drill and tap the clamp and attach the aluminum to it to fill the gap? If not, yeah, okay, everything is powder coated, but who is ever going to see the steering stops? You could drill and tap those, couldn't you? Glue and screw spacers on it there? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 09/30/22 at 08:28:12 Some good ideas there, JOG. I am still mulling things over. In the meantime, I am getting one of the Dodge Dakota trucks out of my shop. Two was too many! Lots of vehicle moving going on just to work on this or that. While a giant hole has been exposed in the vehicle inventory, I am taking advantage the new found space to build my gantry crane. It will remove yet another large crate and free up more space. My shop is like a large game of Tetris. :o |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/12/22 at 13:43:21 I picked up my Antigravity 801 battery back in February this year. I charged it when I got it, and it has been sitting unused since. I am not that experienced with lithium ion batteries. I know that lead acid, and even some sealed gel cell batteries can lose some charge sitting over time. So I decided to put the special lithium ion battery charger on it to keep it charged. Got say I was pleasantly surprised when the charger said it was full in less than a couple minutes! This battery hold a charge on the shelf very well. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 10/12/22 at 16:19:14 Lead acid and AGM lose 1% charge per day. Lithium Iron Phosphate loses 1% per month. |
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Title: Re: 1987 Savage Street Tracker build Post by antmanbee on 10/12/22 at 18:38:45 Could you link the incandescent tail light you got? I'm needing a tail light for a project of mine and was almost going to get the LED one you first had. Glad I read through your thread and didn't buy it. Thanks |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 11/25/22 at 21:58:32 7C6346414B424E5D442F0 wrote:
How is your progress going on this project, The Sneeze? Love everything you’ve done, but haven’t heard anything for awhile. I hope you’re doing ok! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 11/30/22 at 08:02:41 Life has been a bit crazy lately. I just got in late last night from the last travel trip for around three months. I can honestly say I am tired of traveling. On that note, I hope everyone had a good Thanksgiving holiday! I am looking forward to getting back into my shop and getting some progress, but now it is too cold to paint the engine cases. I plan on picking up a respirator so I can get the temp up enough to paint inside my shop with the doors closed. This morning it was 12 degrees outside, and a snow storm is headed our way for the next three days. Winter weather hit like a light switch this year. We literally went from mid 70's to upper 30's and low 40's. So much for fall... ::) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 12/06/22 at 08:47:24 Antmanbee - sorry I overlooked your question. Here is the link on Fleabay where I got the tail light. https://www.ebay.com/itm/183876652361 |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 12/27/22 at 04:45:30 796643444E474B58412A0 wrote:
I made an aluminum block that attaches to the tab on the front of the frame. It only requires drilling a hole to attach it. I am out of town until January 2 - I will take a photo when I am back home. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 12/27/22 at 06:27:38 Thanks, Dave. I was thinking the same thing, but maybe use JB Weld. Not a huge problem, just glad I didn't put another dent in my new paint job. |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 12/27/22 at 10:32:32 The sneeze, this might not be relevant or helpful, but I figured I’d share it. My old Ducati Monster had adjustable stops. They were ridiculously simple, just bolts with lock nuts. Grub screws could possibly work as well, although the JB welded aluminum blocks would likely be much easier to do. Best of luck with whatever solution you come up with! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/14/23 at 15:36:23 I have been missing from this thread for a while! I got a wild hair today, and came up with a solution to my steering stop. I made a small plate from 3/16" steel. and drilled some matching holes in both the plate and stop on the frame. I will use some nylock nuts on the screws to attach it. Easy peasy. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/14/23 at 15:37:09 Stop stop with holes |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 04/14/23 at 22:05:29 Nice to see an update on your project, The Sneeze! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/15/23 at 15:47:34 Time to put my measurements to the test. Here is full lock, both ways. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/15/23 at 15:48:21 Full lock the other way. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/15/23 at 15:49:08 And... we have clearance, Clarence!! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/15/23 at 15:50:31 It's a little closer to the tank on one side, but walking with the bike is the only time it will be turned that far. |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 04/15/23 at 17:36:25 I like your little fix. Please don't take this as a criticism. I'm just sharing an idea that popped into my head. This is in the spirit of hindsight being 20/20. I go through this kind of stuff all of the time and like you, I find a solution. It usually works out fine as your solution will. I've also found that sometimes (usually after the fact) I've overlooked something. If this were my problem, I would be asking myself if I might b happier with a DC Motive top clamp for $170 or whatever they cost. I'm pretty sure their clamp would clear the tank without modifications and probably look a little nicer than the modified lower clamp. Of course, I usually realize this after I've invested time and money into the item that caused the conflict! ;D No corners on this one: http://https://images.squarespace-cdn.com/content/v1/599a7976579fb3a4cb84b290/1547545118356-143RRGHQ0IQJ8W6D2ITR/TCS065-3.373.jpg?format=1500w |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/15/23 at 18:33:34 No criticism assumed. I like creating, and those tend to be my most enjoyable times in my shop. I am out about $1.50 in hardware on this fix. It came out cleaner than I expected. There are other areas of this build where I went a bit overboard money wise, but I still try to follow the K.I.S.S. principle as much as I can. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 04/16/23 at 10:20:16 Problem solving is what creates stress , must be a love hate thing. I hate it but repeatedly do it so I must love it. Also gets me a great sense of achievement/accomplishment to fix a project stalling hiccup. Good job ! Just an everyday thing when you constantly test yourself as a builder. I guess it’s fun ? The ride is the ultimate reward , now that’s FUN ! Rule #1 Don’t sweat the small stuff Rule #2 It’s ALL small stuff Ya got to live by it. 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/16/23 at 10:33:41 This explains a lot... |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 04/16/23 at 13:31:24 Thanks for that picture. It's the best. Lovin your powder coating. Can't wait to hear about your finished project. What cam are you fixin to run in your engine? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/16/23 at 14:34:55 It's a '95 DR650 cam, I believe. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 04/17/23 at 12:07:30 I've toasted a couple of left side main bearings. Just figured that out. I think the DR cam might be the reason. I didn't drill holes in the lobes. I'm thinkin maybe those holes aren't intended to lubricate the lobes and rockers. My cam always looks great when I inspect. So, maybe the holes are intended to spray oil forward to cool the valves and send oil down the forward drain to lube the left-hand main bearing and balancer bearing. If you haven't already drilled the holes in the lobes, I would do it before you put the engine in the bike. I know I've previously taken the position that those holes aren't necessary. I based that on the fact that my lobes & rockers were holding up great. I didn't see the main bearing issue. Always something new to learn. More to come. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/17/23 at 13:40:52 I have not painted the engine case yet, so the top end is still apart. Do you have any details on size/location of these holes on the lobes? |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 04/18/23 at 12:39:18 I use a cam sprocket and the stock cam to set up the hole location. I install the sprocket on the stock cam along with drive pin, then lightly tighten the bolts. Grab the sprocket in a machinists vice and align the stock hole with your drill head. The drill bit should be parallel with the vertical axis and centered in the stock oil hole. Adjust the cam sprocket in the vice and the milling table until alignment is correct. When alignment is correct, lock the vice tight and lock the mill table. Then I carefully remove the sprocket bolts and switch out the cam. Don't loosen the vice, keep the sprocket locked in place, just remove the two bolts and leave the sprocket clamped tight in the vice while you remove and replace the cam. That puts the drill in the exact same location on the DR cam lobe. Lightly tighten the bolts so as not to disturb the alignment. Start with a #1 center drill and finish up with a #47 drill. I suggest solid carbide tools, but HSS might be OK (never tried it, too chicken). Repeat the process for the other cam lobe. The hole in the right-hand end of the cam (in the center of journal) should also be a #47. The DR cam only has a hole equivalent to a #54 in this location, so you should also drill it with a #47 bit. So, first set up the stock cam and align drill to existing hole. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 04/18/23 at 12:41:14 Without disturbing sprocket, remove stock cam and install DR cam, then start drilling first lobe. Repeat the process on the second lobe. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 04/18/23 at 12:42:34 Once the holes are drilled, break the sharp edges with a small oil stone. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 04/19/23 at 11:54:43 DragBikeMike motivated me to make a simple device to hold the cam while it is drilled....and he even supplied me with the drill and countersink! If you want to use it you can pay shipping both ways.....or send me your cam for drilling. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 04/19/23 at 12:01:12 Thanks for the offer, Dave. I have a drill/mill in my shop, so it shouldn't be hard to do it. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 05/27/23 at 14:34:41 Now that my Kawasaki KZ750 is on the road, and my truck project is on hold until the funds are available (selling the KZ), it is finally time to officially get back onto my street tracker project. No more distractions. I have over 95% of what I need to get this bike going already in my shop. It should only be a matter of labor to hear this one bark. She is back on the lift, boys! 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 05/27/23 at 20:49:50 Woo hoo! Happy to see you’re getting back to this project! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/04/23 at 12:18:35 I have been fussing about with masking today. Getting the engine cases ready to paint, now that the temps here are warm enough. I will hang this off my engine hoist for painting. I still need to sand all the case surfaces, but I didn't want to scratch the cases during that process. And damage to the masking tape will be replace prior to painting. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/04/23 at 12:19:05 other side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/04/23 at 12:23:20 I will be using PJ1 Fast Black engine and case paint, satin black. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/04/23 at 15:31:14 first coat |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/05/23 at 12:14:42 Ooh Fast Black 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/05/23 at 23:02:42 Studebaker needs more air time , tracker looking sharp. 12” shocks ? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/06/23 at 08:38:16 Either 12" or 12.5", I can't remember. The Studefrankenbaker project just requires more money. I am at a point with that where I can't move forward without spending some cubic dollars. I think the only thing I am missing for the Savage motor is a base gasket. I can't order that until I get a deck height measurement. My hold up on the tracker was the temperatures were too low around here to paint, but Spring is here and things are warming up nicely. So when I finish painting the cases, I will get the piston installed, put the jug on and take some readings. It's about time for some refresher lessons by going back through all of DBM's posts. 8-) Edit: I have a stock cylinder base gasket on order, along with some other various o-rings I overlooked. I will use the stock base gasket for measuring the deck height. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/09/23 at 15:29:14 The nugget finally has a new look! I have waited all winter to get this step done. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/09/23 at 15:29:44 the back side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/25/23 at 12:40:18 Engine assembly set to begin. The first step is to get the head assembled so the deck height and valve clearance to the piston can be checked and measured. Only one spring will be used for this, to make it easier to rotate the crank slowly. Once all is checked and measured, and any changes made (if necessary), the second valve springs will be installed. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/25/23 at 18:07:42 New spring seats installed |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/25/23 at 18:08:47 Putting the valve seals, valves, and springs in |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/25/23 at 18:10:19 Valves ad springs are in. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 06/26/23 at 03:12:27 Looking good! I don't see the little wire scrubby thingy that inserts in the head to filter out the oil spray in the breather. Don't forget to put that in before the final assembly. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 08:32:09 310A0710010D16100B030E11620 wrote:
See the pic in reply #830, top right of the cylinder head - it is sitting on the rag waiting to be installed. This assembly is only for the deck height and valve clearance measurements, and it will be torn back down. All those small details will be addressed on the final assembly. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 06/26/23 at 10:06:06 Building engines is Big Fun Looking good |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 13:15:30 For the deck/valve clearance measurements I am using the old head gasket, which was apparently smeared pretty heavily with silicone. Everything will be cleaned after tear down before final assembly. You can see the original dirt deposits in the clutch and mag areas, which will be cleaned out as well. Got the modeling clay on the piston, ready for the head to go on. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 13:16:19 All greased up and ready to party!! :o |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 13:17:37 I think this one is going to be a stunner once it's sitting in a silver powder coated frame! Can't wait to put it in it's new home. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 14:41:48 I haven't played with clay for something like 60 years! This is the Exhaust side. Plenty of piston to valve clearance. |
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Title: Re: 1987 Savage Street Tracker build Post by springman on 06/26/23 at 14:41:59 That is impressive. Looks beautiful. I wish I had that skill set! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 14:43:34 This is the intake side. Apparently I needed to wipe down the piston better, or use more grease. It's easy to see that there is more piston to valve clearance than the exhaust. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 14:44:33 The deck height is right at the target of .040". |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/26/23 at 14:46:55 Now is time to tear it back down to the block, and start cleaning everything in prep for the final assembly. I still need to finish cleaning the outside of the cam cover, and replace the rockers and shaft seals. More to come in a couple days! |
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Title: Re: 1987 Savage Street Tracker build Post by zevenenergie on 06/29/23 at 04:28:19 All looks very professional. Bless you. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 06/29/23 at 15:42:25 Love what you've done. Thanks for the pics of the clearance checks. Your clays look great. I like the way you only used the inner springs to keep the turning resistance to a minimum. The head is the cleanest I've ever seen. How did you get that sparkle? Hope this tip isn't too late. You can put your crankcase in the frame. Remove the cylinder studs and install the cylinder & head. Then insert the cylinder studs and finish assembling the head cover. That way, you won't tear up your beautiful silver powder coating on the frame. You're correct, your tracker will be a "stunner". |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 06/29/23 at 15:52:58 Not too late for that tip! I got side tracked by a neighbor to try and repair his crappy welds on a roll bar for his hot rod. I asked him to let me help him initially, but he wanted to try and weld it himself. With the wrong equipment. Lots of grinding before any new welds could go down. I am now two days into what would have been a 2 hour job. My shoulders and neck are already sore and it isn't finished. The cylinder head is freshly ported and painted. The head work was done by Built Motors. The company is owned by one of the machinists from Thumper Racing. Thumper closed, and sold most of the equipment To Kevin, who then opened his company. He did a great job, using some of your measurements and some of his own porting knowledge. I will definitely put the bottom end in the frame first. May be a good time to replace the cylinder studs, anyway. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/01/23 at 14:05:57 Today I disassembled the cam cover. Listen, boys and girls... using the whole tube of silicone is not the answer to an oil leak (or ensuring there won't be one). After an hour of scraping, I have about 95% of the excess removed. It was squeezed into every hole and cavity. Even into the cam area. I have never seen this abuse of a sealer this bad before. If you have to use more than a thin (THIN!) layer, something else is wrong. I finally have this part ready for chemical cleaning. The top will get the same satin black engine paint. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 07/02/23 at 14:05:17 Sneeze , An abuse of sealant clearly indicates lack of knowledge and/or working experience ! Meaning : they have never had to clean that crap OFF Not just in motorcycles , I’ve seen sealant destroy an engine. It is pleasing to see your misery , everything should be spotless before assembly. 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 07/03/23 at 01:03:20 One of these makes sealant application a breeze. Perfect, exceedingly thin layer of sealant every time. Works like a paint roller. Super cheap and easy to make. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 07/03/23 at 01:10:52 This old post provides the specifics. BTW, I love the Permatex Optimum Grey and Optimum Black sealants. They are both very easy to remove after they have been in service. The grey is a bit easier to remove than the black, but both are very easy to apply and work great. The black just sticks a bit better than the grey. Good stuff. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1525551307 |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 07/06/23 at 11:28:32 DBM, Have you ever used Permatex gasket eliminator , grape jelly stuff ? It’s an anaerobic purple jelly. Just don’t get it in the aluminum thread holes. Being anaerobic once the bolt has pulled some into threads it becomes loctite.. I always want to use it on just the main case halves but I’ve been using that 3M yamabond forever , maybe next engine ! It $$ too , I could send you a tube to try if you want , great stuff just remember what you’re working with. It’s good for small/tiny stuff as well as giant equipment. Have never had a leak , against gear oil , motor oil , hydraulic fluid , coolant it’s an awesome sealant. It also fills very small gaps and imperfections. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/12/23 at 13:10:10 To measure my deck height and valve to piston clearance, I had to have a cylinder base gasket installed. I had inadvertently thrown out the old one when I disassembled this motor. I had to use my new one. I believe it is a factory gasket, and comes with a bead of sealant around the perimeter. By installing it, I figured it would no longer be useable after removing the cylinder. I was a bit surprised when I took the cylinder off. I guess the sealant must be too old and no longer pliant. It doesn't seem it would seal very well when torqued. Anyone else see this sealant condition upon disassembly? :o |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/12/23 at 13:10:44 Another view |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/12/23 at 13:12:44 I had to carefully scrape the bits from the case seat for the cylinder, so none of it would get down into the crankcase. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/14/23 at 12:58:40 I needed to tidy up the workbench and get better organized for the motor assembly. Well, this chunk frees up some bench space! It's been quite some time since this was sitting in the frame. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/14/23 at 12:59:25 Other side |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/14/23 at 13:00:53 I hand tightened the side covers on it just to make it easier to wrestle in there. They will be coming back off to work on all the internals. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/15/23 at 13:23:53 I had to post this after I spent a good 30 minutes looking for my old cam chain tensioner, only to finally remember I shipped it to Versy as a core. Sheesh!!! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/16/23 at 15:15:28 What twisted, demented Japanese engineer decided a 9mm thread was a good idea for the cylinder/head studs??!! I was going to replace my studs, but I can't for the life of me find 9mm nuts. The only ones I found were in a bulk of 50 for over $200. Maybe I won't replace the studs after all. Sheesh. :-? |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 07/16/23 at 18:37:24 If you don't have the 9mm nuts, how do you intend to install your cylinder head? The cylinder head is held down with four 9mm nuts (three acorn, one plain flanged). Use the one plain nut with one acorn nut to remove your studs (using the "jam" method). Install the plain flanged nut with the flange facing up. Then install an acorn nut. Jam the two nuts together and remove the stud. Repeat for the next three studs. You're gonna have to remove at least the right-rear stud in order to get your cylinder and head installed. There isn't enough room between the stud and frame to get those components past the stud. Best to remove all four studs. As long as the studs are straight, I doubt you will need to replace them. This old post might be helpful. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1609889036/0 |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 07/17/23 at 03:41:26 It is important to use the acorn nuts, as they seal oil from flowing out of the head. The left front stud has oil flowing down around the stud to the lower crankcase, it is the drain for the head. At least one member has had an oil leak when this area was not sealed properly. The top of the right rear stud is inside the cam/rocker area and in the oil spray area. About 2" down the stud passes through an area where it is exposed to the air flowing through the head from the passage alongside the exhaust port back the right side of the engine to the area alongside the intake port. One member had an oil leak in this area when he did not get the copper washer/nut sealed properly. The left rear stud also has an acorn nut but is exposed to the air. at the top of the head....I am not sure why they used an acorn nut there and not on the right front where they used a plain nut. Follow DragBikeMike's advice for installation of the nuts.....leaky head studs are a nuisance! I did my engine long before Mike did the analysis on torque values and I just applied a small amount of sealant on both sides of the washer and used anti-seize on the threads and it has been working fine - but Mike's method is far more precise and based on science! |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/17/23 at 08:09:04 I have all the nuts. This motor has been apart for so long I didn't realize one of the four wasn't an acorn nut. I am overthinking things again, or just not paying attention. One of my studs has some corrosion on it which is why I decided to replace them. Thanks for the easy solution to my stud removal dilemma. 9mm hex nuts are not easy to find. Any input on the bead of sealant on the base gasket? I wonder if the heat of the motor causes it to melt? Seeing it crumble like that causes me concern. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 07/17/23 at 08:43:22 Thanks for the link to the old thread on this head stud issue. I had obviously read it before, and responded at the time. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/23/23 at 14:28:25 This month has literally been a rollercoaster of emotions (and a lot of time away from my shop!). I spent 2-1/2 weeks in Canada, visiting one of my brothers. Went fly fishing (it was epic!), visited the Canadian Bomber Command museum, played in a poker tournament (came in 2nd, and in the money!), and finished off the trip with a bourbon tasting party in Portland, OR. Three days after returning, my mother passed away after a long battle with Alzheimer's. I had another brother visiting for a week due to the death in the family. The bustle has finally started to die down, and we have no plans of travelling for several months. Time for some much needed shop therapy to get my head straightened back out. The cylinder head fastener mods are first on the list. I just received my #47 carbide drill bit for the cam today. I went to town to the local O'Reilly's Auto Parts store and picked up the Dorman exhaust studs. I have ordered some aluminum bar to make the cam fixture, but it won't be here for about a week. In the meantime, I am going to set up my cylinder on my mill and get the three head bolt threads drilled out. I will get the grade 8 fasteners on the next trip to town. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/23/23 at 14:30:05 So no one has an opinion on the base gasket sealant doing this when torqued? |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 08/23/23 at 16:55:29 if that's a preformed strip on the base gasket, then that's what I would expect, a dry strip that's crushed held in place by pressure, then upon release tearing up into strips. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 08/23/23 at 18:27:32 I'm very sorry to hear about your Mom. That's a tough illness to deal with. Your Mom and your family must have gone through a lot. Have you checked your quench clearance yet? As I recall, you did check it. If so, are you planning to change the quench clearance (increase or decrease)? If yes, then the OEM gasket won't be used. You will be using a copper gasket of the correct thickness to achieve .035" to .040" quench clearance. I agree with Versy on the sealant bead. It looks like it is behaving as expected. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 08/23/23 at 21:45:33 Condolences |
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Title: Re: 1987 Savage Street Tracker build Post by Edub on 08/23/23 at 23:45:33 My condolences man, I hope she’s had a good life. I lost my mom when I was 18, almost 40 years ago. I wish I could say it gets easier. I guess in some ways it does. Hard to explain, I’m just sorry for your loss. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/24/23 at 15:04:56 Thanks, guys. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 08/30/23 at 20:07:54 Not the best day in the shop. I got my new band saw blade, got it installed, and it worked great. I got my aluminum bar cut for the cam fixture just fine. After fly cutting the first side, I started on the second to true up the bar. That's when the phase converter for my mill decided it didn't want to play anymore. It is brand new, installed by a professional electrician. It started to smoke, and two drips of fluid started to run down my shop wall. I cut the power and shut off the mill as quickly as I could. This is the first time I have used the machine (converter installed a year ago). So a $200+ converter is toast. I called the manufacture, and I bought it 13 months ago - it has a 12 month warranty. After using my best "Betty Davis eyes" over the phone, they agreed to send me a warranty replacement for the cost of shipping. Oh - they don't make this converter anymore. So I moved on to the Kawasaki. Time to install the new horn I got. Put it on, turned on the key, no sound. I take it back off, and test it on another 12v source. Make loud sounds. Gee... it's the switch or wiring in the bike. Shucks. :o Time to get out the welder, and weld my butt to the couch with a cocktail in my hand. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 08/31/23 at 02:18:07 Some days can be frustrating like that. I have a few of them now and then.....and sometimes a good day comes along and helps the recovery. The good news is that you aren't doing this as a business and trying to pay off the bills with your profits! |
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Title: Re: 1987 Savage Street Tracker build Post by Bob Scogin on 08/31/23 at 07:02:30 5B4461666C65697A63080 wrote:
I hear you. Sometimes shop work, which should be a major source of enjoyment, is a source of frustration. Recent case in point --lacing up the 18" rear wheel for my de-cruiserized S-40. A couple of hours of work turned into a couple of days because I just had to step away several times and gather my thoughts. Persistence paid off, however. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 09/21/23 at 18:10:43 The warranty replacement converter did not function properly, either. The manufacture said if it didn't work, I would need to step up to a rotary phase converter instead of a static phase converter. So today I ordered the appropriate size rotary model. At 3 times the cost of the static model. And I will need to have a professional electrician install it. Maybe I will finally have my mill running before October? Maybe? :-/ |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 09/21/23 at 21:09:20 Just in time for fall. Got some time left before the snow. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/12/23 at 07:58:48 Here is the difference between a static phase converter and a rotary phase converter. The static converter is inline with the conduit, the rotary converter is on the floor. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/12/23 at 08:00:35 I have the control box mounted on the wall. I am just waiting for the electrician at this point. He is scheduled for next Thursday. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 10/12/23 at 09:36:49 Looks expensive + labor. Bought my Savage and Ryca kit 10 years ago this month. Built mine with hammers,chisels,saws all,files, grinder,welder. Just imagine what I could do with a mill and lathe or a cnc and a 3D printer. I’ll stick with how I do things , blood,sweat & tears brings me great pleasure. Build on , can’t wait. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/12/23 at 13:58:09 Yeah, the rotary phase converter was $647 after taxes and freight. That motor had to come out of the box using my engine hoist (I was alone). I am guessing the electrician will charge around $200-300 for his work. I just keep reminding myself I have a $2500 drill/mill that I spent only $250 on. So it's still a deal. I am excited to have this new capability in my shop. I have several projects lined up that require a mill to complete. |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 10/14/23 at 04:22:27 A friend of mine had a lathe with the little wall mounted converter.......it never worked properly. It would run for a little while - then shut down. The rotary converter is the way to go and will work well. A local car restorer had most of his shop running through a rotary converter and they worked reliably. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/14/23 at 08:40:52 Yeah, I tried to go the cheapest route. It didn't work out (and rarely does). Sometimes I forget the "do it once, do it right" mantra. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/19/23 at 10:41:21 Yay!!! The electrician is here, hooking up power to my mill. I will finally be able to get back on the tracker motor. First up is a cam fixture to drill the oiling holes. 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/20/23 at 15:31:48 The mill is finally working like it should. Both motors are staying warm, and not heating up. I fly cut all 6 sides, and drilled the first hole for my cam drilling fixture. I have a very limited amount of milling tools (due to be slowly increasing as project needs dictate!). I drilled a starter hole at 7/8" since it was the largest drill bit in my inventory. Now I wait for more cutting tools to arrive. I was offer use of an existing fixture for this job, but I really enjoy making my own. I also have a pin gage set on the way as well (.011" to .060"). The smell of Alumicut in my shop takes me back to my working days. Always liked the smell of that stuff! Moly D, not so much. LOL I have a carbide burr set on the way to do the cylinder bolt mods. The exhaust port studs and the seat cutter are already here. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 10/26/23 at 12:04:01 My big azz drill showed up - 1-15/32" diameter, 1/2" reduced shank. The cam fits really nice and the flange is flush. Now on to the transfer punches, drilling, and tapping the mounting hole for both cam lobe positions. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/17/24 at 07:58:30 And just like that, it's all gone... The wife and I are unhurt, the house is fine. The shop and all it's contents are a total loss. The street tracker, my baja, my truck project, my tools. My retired life. All ruined. We found the building engulfed in flames five hours after I closed the shop for the day. No clue what happened. :'( :'( :'( |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 03/17/24 at 09:24:59 sorry to hear about your loss sneeze all is not lost... and you have a new project. |
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Title: Re: 1987 Savage Street Tracker build Post by FinnHammer on 03/17/24 at 09:29:55 So sorry for your loss, Mr. Sneeze |
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Title: Re: 1987 Savage Street Tracker build Post by zevenenergie on 03/17/24 at 10:05:38 My sincere condolences Mr.Sneeze This is a big loss indeed. |
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Title: Re: 1987 Savage Street Tracker build Post by DragBikeMike on 03/17/24 at 10:26:17 The most important thing is that you and your family are OK. I'm very sorry about the fire. I can't imagine how you must feel. I would be lost without my workshop. Hopefully you can figure out what happened. |
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Title: Re: 1987 Savage Street Tracker build Post by LANCER on 03/17/24 at 16:31:40 It is a terrible thing to loose so much, but you, your family and your home are still safe. Praise God for that. This causes me to pause, and rethink the items that are in our “attached” garage, and that would be safer if kept elsewhere. Tomorrow. |
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Title: Re: 1987 Savage Street Tracker build Post by Tocsik on 03/17/24 at 19:02:25 So glad you didn't lose the house and that everyone is safe. "Things" are replaceable. God speed. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/17/24 at 19:34:11 MIG welding gas. It's inert. Non Flammable. Safe, right? My week or two "shorty" bottle of Argon/CO2 is laying to the bottom left of my toolbox. All 1500 psi of compressed gas. It got hot enough to rupture on pressure alone. It went THROUGH MY MOTORCYCLE LIFT (with the street tracker on it), and hit my toolbox hard enough to bend all the shelves inwards, before coming to rest. Ok, then... |
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Title: Re: 1987 Savage Street Tracker build Post by zevenenergie on 03/18/24 at 01:59:15 I hope you are well insured. I once lost all my vehicles in a fire, but I got more in return than I could have sold them for. It is advisable to hire a company that will claim the damage from the insurance company. They know exactly how it works and you are still in shock even though you don't think so and then you can't think clearly. After I did that, I was reimbursed twice as much as initially from the insurance. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 03/18/24 at 04:37:37 Holy crap , that SUCKS ! What a huge loss , but no injuries and house is ok. It was a nice shop , the kind of stuff I only dream about. Another big bump on the road of life. You and the shop will recover. Hang in there buddy. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 03/18/24 at 07:31:28 Dude! So sorry to hear this. Luckily it was just "stuff". But it's no less heart breaking. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/18/24 at 07:50:08 I have spent a lot of time staring at the remains. Initial fire investigator (more will be arriving) asked a lot of questions, one being did I have any battery chargers in operation. I replied no, because I just put a new battery in my baja, and after it's initial charge I had disconnected it and put it away. After he had left I got to thinking. I had been drilling a lot of holes with my Ryobi cordless drill that day, and when I started I put another Ryobi battery on the charger in case the one I was using ran out of juice. My brain thought car battery chargers when the question was asked. Looking again at the ruins, guess which wall was scorched the worst on the inside? My wood cart for the stove? Nope! The one immediately behind where the bench was that had my Ryobi charger on it. I routinely leave my spare cordless batteries on the charger overnite. I am convinced this was the source of the fire. The next investigator to come out will get an ear full of this, for sure. Lesson learned. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/18/24 at 11:39:03 Here is the last shot of my tracker on the bike lift. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/18/24 at 11:42:48 And this shot is her last resting place. This is the official close of this build thread. I so much wanted to get the chance to ride this bike! I am seriously considering getting another one to start over after all I have learned on this site, with the help of all of you. Definitely one of the friendliest forums on the interwebs! This project may be gone, but I will still be lurking around. Peace out |
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Title: Re: 1987 Savage Street Tracker build Post by ohiomoto on 03/18/24 at 16:35:34 Crap. I feel for you. Hang in there. :'( |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/18/24 at 22:37:28 736C7F6C676C676C7B6E606C090 wrote:
What kind of companies do that, and how do I go about locating one? We have AAA for our homeowners and vehicle policies. |
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Title: Re: 1987 Savage Street Tracker build Post by zevenenergie on 03/19/24 at 00:22:19 I live in Europe, so I can't give you addresses, but because the fire was large and several houses were damaged and it was in the news, I was approached by several companies that offered this service. I think if you were to ask a law firm that does insurance matters, they might be able to help you find people who specialize in this. But you can also google this text: Fire victim? We ensure maximum reimbursement. I sure lots of results come up. In my country, there are no costs associated with counter-expertise for insured persons. |
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Title: Re: 1987 Savage Street Tracker build Post by zevenenergie on 03/19/24 at 01:00:52 I just submitted this question to Chatgpt, which is artificial intelligence. User Say i live in Northern Nevada and I had a fire in my hobby shed with engines (bike,s) and all kinds of tools in it and everything was lost. How do I go about getting everything reimbursed by the insurance company? And how do I call in counter expertise to handle the damage? Chat gpt: I'm sorry to hear about the fire in your hobby shed. Dealing with insurance claims and assessing damage can be a stressful process, but there are steps you can take to make it smoother: Contact Your Insurance Company: Notify your insurance company as soon as possible about the fire and the extent of the damage. Most insurance policies require prompt notification of any incidents. They will guide you through the claims process. Document Everything: Before cleaning up or making any repairs, document the damage thoroughly. Take photographs or videos of the entire area, including any damaged items and the extent of the destruction. This documentation will be crucial for your insurance claim. Review Your Policy: Familiarize yourself with your insurance policy to understand what is covered and the process for filing a claim. Pay attention to any limitations or exclusions that may apply to your situation. Provide Documentation: Your insurance company will likely request documentation to support your claim. This may include receipts, appraisals, or other proof of ownership for the items lost in the fire. Provide this information promptly to expedite the claims process. Work with Adjusters: Your insurance company may send an adjuster to assess the damage and determine the value of your loss. Cooperate with the adjuster and provide any additional information they request. Consider Hiring a Public Adjuster: If you're concerned about the insurance company's assessment or believe you're not being adequately compensated, you can hire a public adjuster to represent your interests. Public adjusters are independent professionals who can help you navigate the claims process and negotiate with the insurance company on your behalf. They typically work on a percentage of the final settlement. Keep Records: Throughout the claims process, keep detailed records of all communications with your insurance company, including emails, letters, and phone calls. This documentation can help protect your rights and ensure you receive fair compensation. Review Settlement Offers: Once the insurance company assesses the damage and determines your claim, they will provide a settlement offer. Review this offer carefully to ensure it adequately covers your losses. If you have any concerns or questions, discuss them with your insurance company or a legal professional. Dealing with insurance claims can be complex, especially after a traumatic event like a fire. Don't hesitate to seek support from professionals or legal experts if needed. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/19/24 at 21:11:04 Thanks for the tips, zevenenergie. Two days after the disaster, AAA is already trying to deny stuff. I am actively seeking legal coucil. I knew this was going happen! Insurance sucks... |
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Title: Re: 1987 Savage Street Tracker build Post by Dave on 03/22/24 at 03:06:22 Deb and I were out of town last week and I could not access the forum. I am so sorry for this disaster.......it has to be horribly upsetting to have lost so much. There is so much of your time and investment gone, and so much more is needed for cleanup and getting back what you have lost. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/22/24 at 08:41:10 I read the fine print in our policy. It states "motor vehicles, and parts for motor vehicles, whether attached to a motor vehicle or not, are not covered". Legal council will not be able to overcome that. With my baja (value $25,000), my truck project ($20,000+ in parts), and the street tracker ($5,000+) it amounts to a massive loss that I will not see any return on. I will be able to claim the loss on next year's tax return, though. Not much of a consolation, that's for sure. This June would have marked 20 years of ownership on the baja. End of an era. I have decided that it won't get replaced. Luckily the Green Monster (Kawasaki 750) was in the front garage. I am still trying to decide if I will restart the truck project. Or the tracker. I so wanted to see how that bike rode. :'( Being retired, our nest egg will only go so far, and coming up with another $50k to $60k in toy funds does not appear to be doable. |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/22/24 at 08:48:48 There will be a shop 2.0, which is a small ray of sunshine. Shop 2.0 will be better. How much I get for all my equipment and tools will have to be seen. 40 plus years of tool and equipment acquisition is difficult to inventory, but all I have is time. Initial fire cause investigation is pointing to a Ryobi cordless battery charger I had on one of my benches. The charger was plugged into a power strip. Don't leave your batteries on charge overnight, kids. Important safety tip. |
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Title: Re: 1987 Savage Street Tracker build Post by Gary_in_NJ on 03/22/24 at 09:16:00 Good tip on not leaving chargers unattended. I do it all the time...but no more. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 03/22/24 at 15:31:25 2.0 bigger , betterer ? 8-) |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/22/24 at 21:02:35 Betterer, but not bigger. Stem wall foundation is okay. Going to build the same building on the existing foundation. |
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Title: Re: 1987 Savage Street Tracker build Post by zipidachimp on 03/23/24 at 11:49:45 Don't know what to say: 'sorry' sounds so inadequate. I've been so paranoid about fire in my rented garage such that I've never unpacked my cheap welder! Planning a fresh start may relieve some of the pain. Cheers! 8-) Keep us informed. |
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Title: Re: 1987 Savage Street Tracker build Post by verslagen1 on 03/23/24 at 17:37:05 certainly looks wise to investigate fire safety regarding battery charging. |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 03/23/24 at 18:28:07 Sneeze , Where’s the Green Meanie ? |
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Title: Re: 1987 Savage Street Tracker build Post by Ruttly on 03/23/24 at 18:29:42 2.0 , fire suppression system , sprinkler system ? |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/24/24 at 07:35:57 Rutt - the Green Monster is parked in my front garage, safe and sound. That will end up being my first project in shop 2.0. It needs the right crank seal replaced, which requires splitting the engine cases. A sprinkler or fire supresion system is definitely on the table for shop 2.0. |
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Title: Re: 1987 Savage Street Tracker build Post by zevenenergie on 03/24/24 at 09:22:27 There are also smoke detectors that are connected to your phone. https://www.coolblue.nl/en/smoke-detectors/smart-smoke-detectors And Fire retardant impregnation https://www.flametect.nl/en/ A layer of plasterboard on the walls and ceilings works wonders. And I would also install an overhead crane. The wet dream of all hobbyists :) That was what sally was thinking about during this sene. https://www.youtube.com/results?search_query=orgasme+van+whan+sally+met+harry |
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Title: Re: 1987 Savage Street Tracker build Post by TheSneeze on 03/24/24 at 11:23:18 I had a gantry crane in the shop. The upper I beam melted in the fire. |
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