Dave
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SuzukiSavage.com Rocks!
Posts: 18098
Camp Springs, Kentucky
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You need to go to the top of RSD section, and open up the Sticky for Bike Builds....there are plenty of Cafe' builds to review and get ideas.
I have been living with my build for a couple of years and 4,000 miles, and I have learnt' a few things.
REAR WHEEL. Unless you try switching to cast wheels (which is a project in itself), you are going to have to have a rim laced on to your wheel. An aluminum rim needs to have the proper spoke angle, and if you just buy a random one off eBay the chances are the angle will be wrong. Buchannon Wheel and rim will punch the rear rim for the Savage Hub, provide stainless spokes, and lace it up. I would count on about $ 400 for the swap. Several of us have laced up our own wheels, and saved $ 100 a wheel. It is not all that hard - but does take 3-5 hours each when you are learning how to lace and true. You need to figure out what rim width you want....see below.
TIRES The tradition is to run a 100/90 front tire and a 130/70 rear wheel. The problem with that is that we all were using a 2.50 wide rear rim, and a 130/70 tire is made to fit on a 3.50 wide rim. The 130 tire is therefore rolled and pinched too narrow and there is too tight of an arc at the tread. It wear the center of the tread out too soon, and it rolls tread over onto the sidewall where it is not useable. Currently I am running a 110/80 rear tire and it is plenty of tire on a 2.50 rim, and it is plenty of tire for this bike, and I am running a 90/front tire. If you want a 130/70 rear tire - then get a 3.50 wide rear rim.
SWING ARM - You don't need to modify it if you are not running the vintage Firestones or some other really tall tire. If you switch to a Kawasaki front pulley to change gearing - you will have to modify the swingarm for clearance if you have an 18" rear wheel.
PARTS - I got my rear sets, shift/brake linkage ball ends, and a few other parts from Dime City. I got the seat, seat base, side panels, kick stand mount, and rear set mounts from RYCA. My speedometer is a Trail Tech Vapor - also the Acewell is a recent newcomer that appears to be a nice one. For a headlight I would look on eBay for a nice one from an older bike - the headlight from a 70's street bike would be a good fit.
There are several threads going on right now about fork lowering, shocks, etc.
Dave
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