I was not satisfied that the cut up rubber floor mat was the best solution to the pulley wobble.  The pulley hub has a machined stub that extends into the wheel hub - but the sizes don't match and it allows the pulley hub to wobble.  This is the recess in the wheel hub where the pulley hub slides into......and the wheel bearing is visible.


I first bought a piece of brass tube 2" OD x 1.75" ID from Online Metals.


I then put the pulley hub in my lathe and machined the stub so the brass tube was a tight fit.


I then machined the brass to be a slip fit into the wheel hub recess shown in the first photo.


Then to allow more axle travel to the swing arm that I extended the lenght of the axle slots, I used some stainless pieces that I bought from Online Metals to make some axle adjusters that have more travel than the stock ones.


I then mounted everything to the bike.  The pulley no longer has any wobble, and it appears that this is a better cure than the rubber floor mat pieces.....as long as it proves to be durable.

I just finished buffing the paint, and put the bike together.  The only thing left to do is finish the tank badges and install them.







I am very happy with the way it turned out.

Great job. I like the looks of your tank so much better than the Ryca cut-down Savage tank.

I'm holdin' out for a video Dave,.. gott's ta' see it on the road...  ...

That's a great looking bike, Dave.
Thanks for your detailed documentation of the build.
Its an inspiration to all of us.

Dave, that is beautiful.  Looks fantastic.  That tank really sets it apart and the paint scheme and quality is amazing!
Gerry

I even like the hound dog too.  

Thanks for all the great comments.  I can't wait for a few hard rains to wash the salt off the roads.....and then some warmer weather.

pgamr.....our Black and Tan coonhound Sarah is a great dog.  Real easy going, up to do anything fun......or just sleep.

The nice new paint made the late 70's headlight bucket look a bit shabby.  Today I took the headlight bucket off to strip and paint it.





I also found a silver sticker I bought for this bike that I bought from the Vintage Decals people.  Just in case someone feels this bike is not road worthy...I mounted this on the right side of the swing arm near the pivot point!


It is hard to photograph the reflective surface...the sticker reads:

SUZUKI HEREBY CERTIFIES THAT THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS