Serowbot wrote on 01/29/16 at 16:10:19:

I don't know where you get the $1000 estimate, but if you read my posts, you'd know I was looking for cheap and affordable mods.
Opening up the port costs me the price of a dremel set of diamond drills and discs, which is about $12, since I already own a $25 dremel.
I don't know how much a higher compression piston will cost me though, but it shouldn't be more than a hundred bucks.

Concerning the 25t pulley,
Any reason you can't start out with a pulley like this, and just machine an adapter for it?

http://www.ebay.com/itm/NEW-Hot-Bodies-Pulley-25T-108632-NIB-/290892651307?ha...

If you think you can spend 5 minutes with a dremel tool and throw in a new piston and get a ton of extra HP, and someone will build you a custom pulley for $30, then you will run 85mph all day it' time to PUT THE X BOX DOWN AND COME BACK TO REALITY!  
Get the bike FIRST, and RIDE IT in the REAL world. Do you live somewhere there is no speed limit or other traffic? If you think you can and should ride real fast all the time, get a bike that's made to do so. You WILL be disappointed with a Savage quickly then start posting what a hunk of junk it is.
I'm not picking on you, just trying to give you some frank advise.

And add to Versy's list A TON OF LABOR! Ether all yours, or double his total to pay someone else.

justin_o_guy2 wrote on 01/29/16 at 17:06:30:



Nope.....it I tried all different cutter angles, speeds, etc.  And the pattern always remained even if cutting PVC pipe.  The motor must have been wired incorrectly, and it was somehow out of phase internally and vibrated way too much.  Even with the belt removed and just the motor running the handles on the lathe vibrated badly.

Now that the motor is rewired....it cuts great!

You are really to focused on the exhaust port......and perhaps on the HP and torque curves.

The ring in the exhaust port measures 34mm in diameter.  The exhaust header has a 2" diameter chrome outer pipe - but inside that there is an inner pipe that is much smaller.  That inner pipe has a bit of a cone at the cylinder end, and the cone has a crimp in it that appears like it might allow the exhaust pulses to pass between the inner/outer pipe.  That cone is only 30mm in diameter, and the inner pipe then epxands to 34mm for the entire length of the pipe.  Therefore.....the entire header is the same size as that ring you are so intent on removing.  As I have said earlier....the little ring is not going to do much of anything on a stock bike, and cruising at 80 mph is just not what the Savage is made to do,

My bike has a lot of engine improvements and makes a lot more power than a stock engine, and I have the double Kawasaki pulley change.....and I do believe my bike could cruise at 80 mph - however my Ninja 250 is completely stock and does it better.  The Ninja is supposed to be around 30 HP - but the 9,000 rpm at 80 mph works just fine on the little bike....as it is still 5,000 rpm below the redline. On the Savage you are going to be riding only about 1,000 rpm below the redline at 80 mph.

What you really need for the way you want to ride is a 400 - 500cc twin.  

I also did the 454 mod it cost me around 300 I think.

Now after this mod cruising at 65-70 you will see a decrease in rpm's which was my goal. If the speedo is correct it actually lowered my max speed in 5th gear I think to 85.

Do not know if speedo reading correct bough from the gearing change. And Dave you will need multiple carbite bits I think the guy who did mine told me he went threw 5

You will have some passing power, that will decline sharply after about 60 mph, you will want to be in third before attempting passing on two lane blacktop. The stock bike will probably get to eighty seven or ninety indicated mph. I don't know how true the speedos are at that speed even with the 140/90 tyre.

pg wrote on 01/30/16 at 17:19:20:

Other people, other opinions.  I was looking at getting a 250 when I saw the Savage -- a 652cc single just 50 pounds heavier than the 250s.  Biggest bike I ever had.  Took it from L.A. to OKC and back. On the Interstates I did 1,070 miles in 36 hours, not an Iron Butt, but pretty good.

Had a 21" suitcase, stuff in the saddlebags, tarp and bedroll.  As I said, at 65-70 mph the Savage was just fine.   For Me.  I am now camping on the Vespa, quarter size.  62 mph on the Interstates, slowing for winds and uphills, same as the Semis.

You can either upsize your bike, or you can downsize your expectations.

A Savage in good tune will run 90MOH bone freaking stock, mine would go 95 when I first got it
If I leaned down and put my feet on the rear pegs
as for vibration, like the Rebel it becomes a hum at the high end, not a paint shaker
It's really not that bad
But it is NEVER going to be comfortable running 85-90 all day long without significant work
if you want a lower end bike that will, get on CL and find a used Ninja 500 in good shape
My 2007 was in near factory condition due to a rider that got scared or bored quickly after buying it, cost right at $2k, (more miles would have made it cheaper, but it was literally cherry beyond needing a carb cleaning) and would run 100 MPH smooth as glass
only reason I swapped it is a case of 'old man knees'
if not for that I'd have it still