SuzukiSavage.com - CONTROLS

John in Kalifornia Full Member Offline SuzukiSavage.com Rocks! Posts: 127	CONTROLS 08/11/12 at 10:38:39 HI all, What have you people used for different controls for the clutch and brake? I think the originals are sort of clunky. Is it feasible to use a different master cylinder? Stuff from a dual sport application might be nice. Thanks, John in Kalifornia
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28668 Tucson Az Gender:	Re: CONTROLS Reply #1 - 08/11/12 at 10:46:44 Most all DP bikes have 7/8" bars... swap would get pretty involved...
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teabowl13 Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 535	Re: CONTROLS Reply #2 - 08/11/12 at 13:25:15 CaviMike has a really sweet set-up on his bike. Pictures and sources for all the parts are in his thread. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1343961685
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rfw2003 Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1108 Yantis, TX	Re: CONTROLS Reply #3 - 08/11/12 at 13:43:19 teabowl13 wrote on 08/11/12 at 13:25:15: CaviMike has a really sweet set-up on his bike. Pictures and sources for all the parts are in his thread. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1343961685 His are all 7/8" mount as well according to the links he gave to bad because I really liked his setup.
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Cavi Mike

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Re: CONTROLS
Reply #4 - 08/11/12 at 19:20:39

Yeah sorry, they don't make those levers in 1in, it's all 7/8. Also, the 7/8 risers didn't quite bolt-on either, they use 12mm bolts vs 10mm on the Savage so I had to make new bushings and buy some 12mm bolts to attach them. I forgot to mention that in my thread. In the end it was all worth it because there are way more options with 7/8 bars than with 1in.

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Paraquat Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2206	Re: CONTROLS Reply #5 - 08/11/12 at 19:30:06 Bore out the 7/8 hole to 1 inch? --Steve
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Cavi Mike

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Re: CONTROLS
Reply #6 - 08/11/12 at 20:16:22

That's a bit more difficult than it sounds. Without access to a mill or lathe, it's either going to come out wrong or be completely unsafe. I'd use a CNC mill or a manual lathe with a 4-jaw chuck to do this. Even if you have access to either of those, you still don't have much room for error even if there is enough room. Going from 7/8 to 1" you need 1/16" per side. That's gonna be pushing it. I popped my brake lever off real quick and snapped this picture, I don't think there is enough room. I suggest getting 7/8" bars and going 7/8" all around.

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Re: CONTROLS
Reply #7 - 08/11/12 at 20:36:26

It starts with finding risers. These are the risers I used.
http://www.ebay.com/itm/7-8-5mm-Riser-Handlebars-Clamp-Kit-Steering-Stem-Hond...
Ironically I machined off the 5mm rise but that wasn't necessary, I just like things the way I like them. I made the bushings from some thin-wall tubing we had laying around the shop but I knew I could easily make them from some carefully cut conduit - no machining necessary - but they would need to be cut crosswise AND lengthwise. A steady hand and a hack-saw is all that's required here and then crush them to the proper diameter. Then go to your local hardware store and pick up the bolts you need. They will need to be 70mm long. I can't remember the pitch but that doesn't matter, just bring a riser with you and fit it up.

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RanDaMan Full Member Offline SuzukiSavage.com Rocks! Posts: 149 Massachusetts Gender:	Re: CONTROLS Reply #8 - 08/14/12 at 07:54:43 Hey Cavi-Mike in your pictures of the brake lever mounted on the handle bars you have a black (brake?) line running from the lever. What is that line? is it a break light line? your break line is obv hydraulic, i cant think of what else it could be
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Cavi Mike Serious Thumper Offline Thumper n00b Posts: 1005 Rochester, NY Gender:	Re: CONTROLS Reply #9 - 08/14/12 at 08:52:05 I think you're looking at the hose that comes from the reservoir. It's a remote-mount setup like most sport-bikes. The Savage setup is integrated.
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Re: CONTROLS
Reply #10 - 08/14/12 at 09:06:16

Cavi Mike wrote on 08/14/12 at 08:52:05:

I think you're looking at the hose that comes from the reservoir. It's a remote-mount setup like most sport-bikes. The Savage setup is integrated.

The line im looking at comes directly from the lever. looks just like a cable brake line on a Bycicle. the line coming from your reservoir has what looks like a stainless braid or spring wrapped around it. i just dont know what the cable is for?

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28668 Tucson Az Gender:	Re: CONTROLS Reply #11 - 08/14/12 at 09:46:10 RanDaMan wrote on 08/14/12 at 09:06:16: The line im looking at comes directly from the lever. looks just like a cable brake line on a Bycicle. the line coming from your reservoir has what looks like a stainless braid or spring wrapped around it. i just dont know what the cable is for? Methinks you're lookin' at the throttle cable... ...
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Re: CONTROLS
Reply #12 - 08/14/12 at 09:58:33

Serowbot wrote on 08/14/12 at 09:46:10:

RanDaMan wrote on 08/14/12 at 09:06:16:

The line im looking at comes directly from the lever. looks just like a cable brake line on a Bycicle. the line coming from your reservoir has what looks like a stainless braid or spring wrapped around it. i just dont know what the cable is for?

Methinks you're lookin' at the throttle cable... Wink

...

Throttle cable doesn't have a wire wrap.
You're looking at the front brake line or hydraulic hose.

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RanDaMan

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Re: CONTROLS
Reply #13 - 08/14/12 at 10:16:28

Serowbot wrote on 08/14/12 at 09:46:10:

RanDaMan wrote on 08/14/12 at 09:06:16:

The line im looking at comes directly from the lever. looks just like a cable brake line on a Bycicle. the line coming from your reservoir has what looks like a stainless braid or spring wrapped around it. i just dont know what the cable is for?

Methinks you're lookin' at the throttle cable... Wink

...

I think youre def right! I couldnt figure out what the heck that was for. Embarrassed

@ VERS I could see the hydraulic line in the back round I just didnt know what the other cable was.

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Dave

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Re: CONTROLS
Reply #14 - 08/14/12 at 14:16:41

RanDaMan wrote on 08/14/12 at 10:16:28:

Serowbot wrote on 08/14/12 at 09:46:10:

RanDaMan wrote on 08/14/12 at 09:06:16:

The line im looking at comes directly from the lever. looks just like a cable brake line on a Bycicle. the line coming from your reservoir has what looks like a stainless braid or spring wrapped around it. i just dont know what the cable is for?

Methinks you're lookin' at the throttle cable... Wink

...

I think youre def right! I couldnt figure out what the heck that was for. Embarrassed

@ VERS I could see the hydraulic line in the back round I just didnt know what the other cable was.

Yep....that is the throttle cable. We use similar cables in Trials to make the cable run along the bar so that the cable doesn't catch on tree limbs.

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