Gheorghe wrote on 09/22/14 at 07:11:18:


Done....Pffffft!  It is "substantially complete".

It looks great.....but you will find a thing or two you want to change as you ride it and gets some miles on it.

I found the rear tail light with built in turn signals to be horribly inadequate if you ride when the sun is shining....it will only be seen if folks are staring at it...it will not get their attention if they are not looking directly at you.  I added a supplemental stop light under the fender that is a really bright Emergency Flasher LED, and I added bright yellow LED turns signals.....they see me now!

The rear tail light should be taken apart and sealed up tight with RTV silicone.  After a couple of rides in the rain my tail light got wet inside, and a few weeks later it stopped working.  My most recently purchased one had a red lense to better tie in with my red paint scheme, and I took it apart and sealed it up before mounting it.  (I don't use tail light turn signals and have "real" turn signals).
http://www.ebay.com/itm/390676538747?_trksid=p2060778.m1438.l2649&ssPageName=...

If you get caught in the rain - you will get a face full of water without a fender.  The first year I rode mine without a fender as I ran out of winter and did not want to spend good riding weather building a fender. The front tire throws water all over you, all over the bike....everywhere!  The next year I built a fender....and it is better as it does not throw as much water onto the engine and wiring up under the tank.  The bike still throws water in your face and up your backside....and on both feet.

You might want to consider adding a "stop" for the rear brake pedal.  Instead of the rear brake pedal flopping around, the stop allows you to adjust the vertical height of the pedal and the brake will work like it used to.  Go to Post #26 in this thread and see how Gerry built his:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1385498224/15

You might also want to use some silicone or Beeswax or something on the seams in the seat.  When that buggers gets wet it oozes water out onto your bottom for a long, long time......and gives you soggy shorts every time you sit down!

Have fun....and get ready to spend a lot of time talking to folks whenever you stop.....folks really want to know what it is!

Am I looking at this pic wrong?  I don't see how the stop works.  The arm either moves the wrong direction to contact the stop or I'm missing something.

The stop prevents the pedal from moving up too far, and it allows you to tighten the adjustment nut on the rear brake arm to set the pedal movement.  All production bikes have a stop built into the system that limits the brake pedal movement up.....the RYCA kit does not provide this and it is a needed improvement.

Here is the brake stop I made for mine, maybe it will help you visualize this a bit better.  The rubber tubing over the bolt keeps the brake pedal from making a clicking sound when the brake is released.

HEY、
how long your rear wheel wire？

George!!  Awesome build!!!  Your post has finally answered my question!  I have been trying to figure out what the solenoid module was.  Now I know.  I am attempting to remove it from my build as well and unfortunately, my skills in electrical wiring are far worse than my mechanical skills.  I can solder wires, but can't read a schematic.  You mentioned that in order to remove it, you need to solder the power wire to the rest of the starter system circuit.  Which is the power wire in the picture included and where would I solder it to?  I am going to assume that I can just cut the remaining wires and leave them in the harness if I so choose?

In the picture, for clarification, the wire colors from left to right are yellow/black, red/white/blue, yellow/green, black/white, and black/red.

Cool!

Very good job!!!