SuzukiSavage.com - The Project: Phase 4

MotoBuddha

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The Project: Phase 4
07/02/11 at 09:04:56

Okay, it's reassembly time, which should be the last phase of this project. This morning I got the front and rear ends installed -- a tricky thing to do singlehanded.

I had a hard time getting the rear brake back together. The new shoes were binding on the drum. So I got out the flat file and wore away a few hundred miles of brake material.

I encountered one small powder coat issue. One shock mount hole on the swingarm had a little buildup on the lip. The stepped bit took care of that in a couple of seconds.

Where I started:

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« Last Edit: 07/02/11 at 15:14:39 by MotoBuddha »

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Abbey Normal YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: The Project: Phase 4 Reply #1 - 07/02/11 at 09:29:17 Looking outstanding!
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SuperSavage Senior Member Offline SuzukiSavage.com Rocks! Posts: 341	Re: The Project: Phase 4 Reply #2 - 07/02/11 at 10:57:31 MB, you've got the Midas touch!
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ralfyguy Serious Thumper Offline Posts: 932	Re: The Project: Phase 4 Reply #3 - 07/02/11 at 11:03:07 I like those tires. Looks better than those old style looking ones on the RYCA prototype.
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skeebo Senior Member Offline Ride It Like U Stole It........ Posts: 328 Fresno, Cali Gender:	Re: The Project: Phase 4 Reply #4 - 07/02/11 at 11:08:37 Looks great!
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MotoBuddha

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Re: The Project: Phase 4
Reply #5 - 07/02/11 at 11:26:40

ralfyguy wrote on 07/02/11 at 11:03:07:

I like those tires. Looks better than those old style looking ones on the RYCA prototype.

I like the looks, sort of like a cross between dirt track and sportbike tires. They're the ones Ryca provides as standard, if you get them from them. I got the front elsewhere because I went with an 18" front instead of 19".

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MotoBuddha

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Re: The Project: Phase 4
Reply #6 - 07/02/11 at 11:35:28

Rats. The threads on the clutch lever perch are stripped. It let go just as it was starting to snug up to the bar. I scrounged a longer bolt from my box since there was a little more hole, but it let go too. My options are to get a new clutch lever perch ($$), or have someone machine a flat recess at the top of the bolt hole so I can use a nut on a longer bolt -- which is the way it should have been done in the first place.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: The Project: Phase 4 Reply #7 - 07/02/11 at 12:11:52 A dremel with a small mill attachment will let you freehand it, Or, if you have a drill press,, buy a drill bit & work the end to do the job or buy an end mill,, not too pricey, be less than hiring it done.
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MotoBuddha

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Re: The Project: Phase 4
Reply #8 - 07/02/11 at 14:35:20

Here's a little detail. The the caps from my handlebar mounts were rusty, so I had them done the same color as the frame. I don't particularly like the way the socket head bolts stick up, but I haven't had any luck finding button head bolts that are long enough. Oh well.

Maybe next year I'll rework the whole top triple clamp and gauge arrangement. I really only need a speedo anyway. Maybe I can figure a way to implement an old headlight bucket with the speedo mounted in it.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28755 L.A. California Gender:	Re: The Project: Phase 4 Reply #9 - 07/02/11 at 14:42:43 How about carriage bolts?
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #10 - 07/02/11 at 14:48:20 I'd need to cut square holes in the caps. Not impossible.
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #11 - 07/02/11 at 15:10:26 I have a temperature gauge I'm thinking of mounting between the tach and speedo. I'd need to find a sender to fit one of the bottom front oil access ports.
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ralfyguy

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Re: The Project: Phase 4
Reply #12 - 07/02/11 at 20:58:11

I got a SS Carriage Bolt at Lowe's to mount my tach with a chrome clamp to the handlebar, just left of the handlebar bracket. Due to the lack of a lathe, I took my cordless drill and stuck the threaded end in the chuck and tightened carefully. Then I put the cordless drill on my front steps, laying it on it's side and holding it down with my left hand and letting it run, I held a file to the square piece on the underside of the carriage bolt, thus making it round. Then I took the file and smoothed out the top of the bolt with the drill running. Next step sanding it then steel wool and last but not least, polishing paste. Looks like chrome bolt now. I basically used the cordless drill as a lathe. Wink

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MotoBuddha

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Re: The Project: Phase 4
Reply #13 - 07/03/11 at 05:51:50

Where did I put them... where did I put them... where did I put them... where did I put them...?

Rats. I can't find the guts to my switch pods. I know I bagged and marked them, and I thought I put them in the box with all the other bagged and tagged items. I've been going through boxes and drawers, but no luck yet. That's what I get for trying to be orderly.

Update: I finally found them -- in a place they shouldn't have been but, in a way, made sense.

But where's the kill switch? I remember not liking how faded it was and that I'd paint it. Other than that... I don't know where I put it.

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« Last Edit: 07/10/11 at 13:10:03 by MotoBuddha »

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28755 L.A. California Gender:	Re: The Project: Phase 4 Reply #14 - 07/03/11 at 06:29:50 MotoBuddha wrote on 07/02/11 at 14:48:20: I'd need to cut square holes in the caps. Not impossible. Nope, don't need to do that. Either get a smaller size or grind the square under the head into a round.
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