SuzukiSavage.com - My RYCA project

sbaugz

Ex Member

My RYCA project - first test drive
03/12/11 at 08:46:41

I've been doing some work on my bike, in anticipation of the kit release. RYCA had my tank and hub.

I installed the lowering kit and upgraded shocks from RYCA. It was a piece of cake. While I was at it, I replaced the brake pads and cleaned up the calipers. Ordered a set of shock boots from cheapcycleparts.com too.

The bars are mounted temporarily. I have to play around with them a little to get the right location. I plan on ordering some custom made brake lines with different banjo fittings and shorter line.

I got the generator cover, belt cover, oil filter cover, and clutch cover powder coated a matte black. Those are now re-installed and not leaking yet! The timing inspection cover is from a VS800 and uses a hex wrench instead of the slotted one that comes on the s40.

I wrapped the header with titanium 2" exhaust wrap from DEI.

Finally, this morning I got out the jigsaw and 4 1/2" grinder and hacked up the fender. The fender will be taken to the powder coater this week for black matte finish. I mocked it up to let you all see what it looks like.

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« Last Edit: 06/25/11 at 18:09:40 by sbaugz »

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: my RYCA project Reply #1 - 03/12/11 at 15:27:54 If you don't like the look of the top of the fork boots, you can grab the top pleat, slide the boot down, then pull back up. The top band of the boot will probably grab the fork and turn inside out as you pull up.
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sbaugz

Ex Member

Re: my RYCA project
Reply #2 - 03/13/11 at 14:50:53

MotoBuddha wrote on 03/12/11 at 15:27:54:

If you don't like the look of the top of the fork boots, you can grab the top pleat, slide the boot down, then pull back up. The top band of the boot will probably grab the fork and turn inside out as you pull up.

Thanks for the tip. I might consider doing that, although I think I might like the fork boots the way I have them.

Got another couple pics today of the header wrap. I used the titanium wrap from DEI. Don't need to wet it when you install and you don't need to spray it with anything, ie, high temp paint.

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sbaugz

Ex Member

Re: my RYCA project
Reply #3 - 03/20/11 at 11:01:11

ordered my stainless brake lines from elite parts on ebay. $31 shipped from Canada. Decided to go with 32.5" black line with a 0 degree fitting on caliper and 90 degree fitting on master cylinder. Will see how that works. Works out to be a solid 8 inches shorter than the stock brake line.
Now, what to do about the clutch and throttle cables.

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: my RYCA project Reply #4 - 03/20/11 at 11:21:56 sbaugz wrote on 03/20/11 at 11:01:11: Now, what to do about the clutch and throttle cables. http://www.motionpro.com/motorcycle/custom/
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jandaso Full Member Offline Do you want fries with that? Posts: 145	Re: my RYCA project Reply #5 - 03/20/11 at 12:38:26 You can also contact Joe@barnettclutches.com he can help you out with The cables and you can order directly with them. I just ordered a cable and there is No need for a middle man.
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B1-66er Full Member Offline I've been everything you want to be. Posts: 124 Eastern Ohio Gender:	Re: my RYCA project Reply #6 - 03/20/11 at 15:56:38 how many feet of that wrap did you need? is it the one inch or two inch?
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sbaugz Ex Member	Re: my RYCA project Reply #7 - 03/20/11 at 16:23:55 15 feet was plenty of the 2" wide wrap. I made the mistake of ordering 15 feet of 1" wrap first and was short about 5 feet. I then re-ordered the 2" in that length and it was fine.
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jandaso Full Member Offline Do you want fries with that? Posts: 145	Re: my RYCA project Reply #8 - 03/20/11 at 17:53:27 50ft of 1" did the trick for me and I had plenty of It left.
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sbaugz Ex Member	Re: my RYCA project Reply #9 - 03/26/11 at 07:16:42 Some minor progress on my bike. I took the stock fender and cut it way down with my jigsaw and smoothed the edges with my grinder. Sanded it nice, had it media blasted and then powder coated gloss black. Trying to decide on tires right now. I am leaning towards the Dunlop K70 vintage tires- front and rear.
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: my RYCA project Reply #10 - 03/26/11 at 07:39:58 Looking good!
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sbaugz

Ex Member

Re: my RYCA project
Reply #11 - 04/16/11 at 16:37:59

more progress, albeit very slow progress.

Got an e-mail from Ryan, telling me my tank is done and the fiberglass parts are getting primed. Only other limiting factor right now is getting the RYCA custom parts powder coated. I would guess any time now my kit will be shipped out.

Patched up the cracked headlight bucket and painted it black with Krylon Fusion matte black.

Mounted the Dunlop K70 vintage tires on the stock front wheel

Painted the front brake rotor black

Added the suzuki decal to front triple tree

Did all the recommended frame cuts for my RYCA kit.

painted the front turn signal fork clamps black

ordered some vintage Harley coke bottle type grips and bar end turn signals and halogen headlight bulb- all from ebay.

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Edgar Senior Member Offline Are you a lucky little lady in the city of light? Posts: 353 San Diego	Re: my RYCA project- updated pics 4/16/11 Reply #12 - 04/16/11 at 16:58:41 I have the same grips in red, how are you gonna install the bar end mirrors? I always thought you had to get specific grips for the mirrors to mount properly
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: my RYCA project- updated pics 4/16/11 Reply #13 - 04/16/11 at 18:39:57 You know, the Ryca kit includes grips -- very much like those from what I can tell looking at the photos. A little skillful cutting with an Xacto will open the ends so you can use barend mirrors (or signals, in my case).
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sbaugz Ex Member	Re: my RYCA project- updated pics 4/16/11 Reply #14 - 04/16/11 at 20:16:46 yes, I know they come with them. I was going to e-mail and tell them I don't need them. I wanted to get a head start while I am waiting and completely finish off the front end.
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