SuzukiSavage.com - Thumpin' Special......On The Road Again!

Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18117 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #360 - 07/08/24 at 07:30:54 After several hours of monkeying around I had the new plunger built. This photo shows the stock plunger with the aluminum spacer I made 6 years ago - and the new plunger not yet cut to length.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18117 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #361 - 07/08/24 at 07:32:54 The one thing I did note about the old aluminum spacer - was the imprint that the stock plunger left. When machined the face of the spacer was flat - now it has a recessed area where the back of the plunger has been pushing on the spacer.....so it is definitely doing work to limit the travel.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18117 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #362 - 07/08/24 at 07:35:48 This is what it looks like installed.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18117 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #363 - 07/08/24 at 07:38:31 This is the hole I drilled and beveled to allow oil to flow into the tensioner body. It is my hope that the oil will act a bit like a shock absorber and cushion the movement of the plunger before it hits the hard stop.
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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5113 Manteca , CA Gender:	Re: Thumpin' Special......On The Road Again! Reply #364 - 07/08/24 at 08:31:35 Good idea , Honda 90s use oil pressure to tension the cam chain.
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Dave

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Re: Thumpin' Special......On The Road Again!
Reply #365 - 07/11/24 at 09:30:29

Every day I get a bit done and a little closer to getting it running again.

I really like the UNI filter. The carb throat and slide show no evidence of any dirt getting past the air filter. The slide does not have any scratches that would show dirt is getting to it, and the piston and cylinder show no evidence of accelerated wear from getting dirty air.

I had ordered a new filter - but once I cleaned and oiled the 11 year old filter it looks just fine. I will use the old filter and keep the new filter for use on the Retro Standard bike.

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Dave

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Re: Thumpin' Special......On The Road Again!
Reply #366 - 07/11/24 at 09:38:37

I will be using 30 weight break in oil for a while. Most builders of car engines use it for 500 miles - I am not sure I will be using it that long. The break in oil has high ZDDP, low detergent, no friction modifiers, no multi-viscosity additives, no corrosion inhibitors. By eliminating all the additives there is more room in the mix for the actual oil molecules, and the thinner 30 weight oil allows for more flow and it does not overly cushion the parts that you are trying to break in. The high ZDDP helps the cam and rockers break in and is a high pressure lubricant for anything that might exceed the ability of the oil to handle alone. I used 30 weight Brad Penn oil when I first built this engine and it seemed to do a good job......I only switched to Lucas as I can buy it local.

The acceptable temperature range for 30 weight oil in the Savage is 70-86 degrees. I will take morning rides while it is still cool - I won't be pushing it for a while and I will keep an eye on the engine temperature.

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Re: Thumpin' Special......On The Road Again!
Reply #367 - 07/11/24 at 09:40:50

The only remaining things to do is put in the oil and the new filter, assemble the side panels and fuel tank, add the gasoline.

I have the rear valve inspection cap off so that I can pour some oil in the head to get a pool of oil in the trough under the cam lobes. That will provide the needed lubrication until the oil gets flowing......I will turn the engine over with the spark plug out until oil pressure and flow is established.

Oh Yeah......I have to hook up the positive battery lead as well! Roll Eyes

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Re: Thumpin' Special......On The Road Again!
Reply #368 - 07/11/24 at 13:39:59

I stopped by a convenient store that is near a local outlaw drag strip and bought some fuel. I will use it for the break in of the piston/cylinder. I will likely start it up and make the first ride with it full strength - then mix in 91 octane ethanol free gasoline and see how it runs. Eventually I will be running 91 octane premium....with or without ethanol depending on where I am riding and what is available.

The race gas is $11.49 a gallon! (I won't be buying a lot of it). Roll Eyes

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18117 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #369 - 07/11/24 at 18:53:05 Tonight I took an old oil filter cover that had a dent and a crack, and repurposed it. In the area that had the dent I attached a piece of aluminum - I bonded it with JB Weld and a couple of screws. I then tapped it for a 1/8" pipe fitting.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18117 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #370 - 07/11/24 at 18:53:59 The backside shows the two screws - they have red threadlocker so they stay where they belong!
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Re: Thumpin' Special......On The Road Again!
Reply #371 - 07/11/24 at 18:55:56

I am going to see if I can use it to fill the oil system and filter housing with oil - then insert a gauge to see what kind of oil pressure I have when the bike is running. I will likely ride it once of twice with the gauge in place - but it will not be a permanent accessory.

The gauge in there for the photo is from a tire gauge and has an end that sticks out to open the tire valve - it will not be used. I have a new gauge arriving in the mail tomorrow.

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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1452	Re: Thumpin' Special......On The Road Again! Reply #372 - 07/11/24 at 19:25:26 Great stuff, Dave! Thanks for sharing!
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DragBikeMike

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Re: Thumpin' Special......On The Road Again!
Reply #373 - 07/11/24 at 23:50:07

Thanks for the tip on that breakin oil. I see it on Amazon. I might actually be able to get it shipped out here. Never seen it in any of the local parts stores.

I'm lovin the simplicity of that test gage setup. Great tool.

I can only dream of 110 octane pump gas. It would be sweet if I could get like 100 octane at one particular station, like Shell or Chevron, but I have never seen anything better than 92 out here. At $11.49 a gallon I can see why it's not easy to find.

I am surprised by the wear on your CCT stop. I checked mine and there is a very slight mark on it but nothing like yours. How much back travel do you have? Do you check the back travel periodically? I set mine at .060" on a new build, then check every 3500 miles. It usually needs adjustment the first few inspections, then settles in and seems to stay at .060". This is my CCT stop after about 27,000 miles. My cam chain has over 66K and is still well under the wear limit. I can't figure why your stop is wearing so much.

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Gary_in_NJ

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Re: Thumpin' Special......On The Road Again!
Reply #374 - 07/12/24 at 05:38:53

DragBikeMike wrote on 07/11/24 at 23:50:07:
I can only dream of 110 octane pump gas. It would be sweet if I could get like 100 octane at one particular station, like Shell or Chevron, but I have never seen anything better than 92 out here. At $11.49 a gallon I can see why it's not easy to find.

Go to your local general aviation airport (or the FBO at a larger airport) and buy 100LL AVGAS. It's not as expensive a race fuel (but dang close) and has the added benefit of being a consistent blend with strict transport rules.

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