SuzukiSavage.com - Double RYCA build Mar 2019 updates

Gyrobob

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Re: Double RYCA Build
Reply #105 - 08/16/11 at 20:31:25

This info is also in the bolt rubbing on the belt thread.

It looks like I have even less clearance than the other RYCA builders.

The belt is almost rubbing on the boss on the case, even with the bolt removed. It looks like I will have to not only use a roundhead allen bolt (probably flattened some), but I'll additionally have to grind the boss down flat with the case, maybe .080 or .090".

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Oldfeller--FSO

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Re: Double RYCA Build
Reply #106 - 08/17/11 at 01:29:38

You can countersink a flat head allen screw to be flush mounted to the aluminum housing if you need to. The countersink is a simple 45 degree countersink you can get from Harbor Freight and the screws you can get from the on-line boltdepot.com place listed on this thread.

http://www.boltdepot.com/dimension.aspx?cc=25&cs=83&cm=19

All the fender bolts on the inside of this fender were flush mounted to the steel fender, so aluminum should be fairly easy to do.

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1181496...

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Double RYCA Build Reply #107 - 08/17/11 at 05:18:21 Oldfeller--FSO wrote on 08/17/11 at 01:29:38: and the screws you can get from the on-line boltdepot.com place listed on this thread. But rather than pay shipping on one bolt, you can probably find one that size at an Ace Hardware for about $1.50.
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #108 - 08/17/11 at 06:08:28 Oldf and Moto, Great idea. Countersink the hole and get a matching allen head screw. I have the "countersinker" already, and I might even have the screw lying around somewhere. If not, I'll try Lowe's or Hommy D'pot. Thanks large.
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Double RYCA Build Reply #109 - 08/17/11 at 11:15:00 But Ace has stainless steel fasteners. Mmmmmmm stainless! And they're carefully organized, unlike HD or Lowe's. They also come individually so you don't need to buy a 4-pack or whatever.
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Gyrobob

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Re: Double RYCA Build
Reply #110 - 08/18/11 at 03:41:58

MotoBuddha wrote on 08/17/11 at 11:15:00:

But Ace has stainless steel fasteners. Mmmmmmm stainless!

And they're carefully organized, unlike HD or Lowe's. They also come individually so you don't need to buy a 4-pack or whatever.

The surgery went well. Both bikes now have 1/16" clearance.

The head of the screw is nearly flush with the existing surface of the boss. The metal in the case at that location is soft!

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« Last Edit: 08/22/11 at 16:46:17 by Gyrobob »

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Double RYCA Build Reply #111 - 08/18/11 at 05:22:10 An afterthought that might be a bit late. You might want to have a vacuum sucking away the shavings as you countersink the hole.
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ralfyguy Serious Thumper Offline Posts: 932	Re: Double RYCA Build Reply #112 - 08/18/11 at 10:38:42 Maybe he stuffed something in there prior to countersinking. Actually the shavings shouldn't drop into the case, they should just go further down the hole meeting the thread. I don't think it is open space between the visible hole and the thread.
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Gyrobob

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Re: Double RYCA Build
Reply #113 - 08/18/11 at 19:09:23

MotoBuddha wrote on 08/18/11 at 05:22:10:

An afterthought that might be a bit late. You might want to have a vacuum sucking away the shavings as you countersink the hole.

ralfyguy wrote on 08/18/11 at 10:38:42:

Maybe he stuffed something in there prior to countersinking. Actually the shavings shouldn't drop into the case, they should just go further down the hole meeting the thread. I don't think it is open space between the visible hole and the thread.

Valid concerns. After I countersunk the hole, there were just a few shavings right there,... unreachable, but still near the surface. I used an electronic equipment duster (compressed 1,1-diflouroethane) with a 1/16" diameter straw stuck into the head, inserted the straw an inch past the shavings, closed my eyes, and pressed the button,... blasting the shavings back out of the hole.

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Re: Double RYCA Build
Reply #114 - 08/22/11 at 08:46:00

I'm trying to get the tanks to line up properly.

As set up by RYCA, the forward tank mounting bracket is supposed to be adjustable. It is adjustable, but it seems to me that the puny little fasteners (size 6 screws) are nowhere near powerful enough to hold that bracket in place with a tank full of gas, a bumpy road, and a big thumper vibrating away underneath.

I see two possibilities.
1. Replace the fasteners with bigger stuff so it will clamp the bracket into place for real.
2. Once I get everything lined up, drill a hole through the bracket and the frame and install a bolt there so the bracket can't move.

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Double RYCA Build Reply #115 - 08/22/11 at 16:00:40 Or, before you make work for yourself, you could ask Ryca if they've had any problems with the bracket loosening or the fasteners breaking.
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sbaugz Ex Member	Re: Double RYCA Build Reply #116 - 08/22/11 at 16:06:50 MotoBuddha wrote on 08/22/11 at 16:00:40: Or, before you make work for yourself, you could ask Ryca if they've had any problems with the bracket loosening or the fasteners breaking. agreed, I wrenched on mine a bit to get it lines up. Have 500 miles on mine so far and no issues.
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #117 - 09/21/11 at 14:31:41 Here's a list I keep updated of all the videos/documents/etc. for a RYCA build. It's in the RYCA update section,.. just click on this link: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1297565987/79#79
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: Double RYCA Build Reply #118 - 09/21/11 at 14:36:26 I've found that I keep one of my drills reserved for taps,.. and I keep a set of dies handy as well. Just about every threaded item from RYCA needs to have the threads "chased" to allow everything to bolt together easily.
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sbaugz Ex Member	Re: Double RYCA Build Reply #119 - 09/29/11 at 17:10:25 what's the status on your builds? anxious to see them.
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