Here is an update to the pulley kit listing to convert your bike to run a Kawasaki 25 tooth pulley.  I have 5 pulleys left, 2 are complete, 1 is machined and needs to be powder coated, and 2 have been cleaned up but have not been machined or coated.  When these 5 are gone it will be the last I make - I need to work on my own projects and stop spending my hours working for others.....I have too many of my own project that are not getting done.

$165 buys a good used Kawasaki pulley that has the machined to fit the Savage and has been powder coated black, a new locking washer, and 2 stainless screws to replace the existing screws that have tall hex heads.  Shipping is included to anywhere a USPS small Flat Rate box will go for the current $ 7.15 shipping rate.  Availability is subject to my stock of used pulleys.

NOTE: The price will be reduced to $160 if you send me a check or money order for payment and I don't have a PayPal fee deducted from your payment.  


Link to Stewmills installation thread:

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1484806731


This is an excellent upgrade for the stock or modified engine.  The stock Savage pulley is 23 tooth - the Kawasaki pulley is 25 tooth and provides a 8.7% overdrive - and this reduces the engine rpm at cruise.  The engine with stock gearing, 140/80-15 tire and 5 speed transmission is spinning at 4,676 rpm at 70 mph, and this pulley conversion will reduce that to 4,302 rpm.  Although that doesn't sound like much - it is more than the change when shifting from 4th to 5th gear (8.1% change).

The Kawasaki Pulley needs to be machined to fit on the Savage, both the front and back sides of the pulley have to cut down, and the metal is very hard.  

Here is a photo of a used pulley before machining, and a completed pulley for comparison.  On the front side all of the metal needs to be removed until it is just a bit below the flat surface.

Nice pics, Dave!
If anyone is going to try this themselves, understand that the splined area is quite hard. The rest of the metal cuts pretty easily, but as you get to the hardened part things get nasty in a hurry. I used indexible carbide inserts, and even they get murdered.
Dave made a mandrel out of a trans shaft. I cut a few of them merely holding the pulley in a three jaw chuck on the lathe and taking small bites.
After having one sail out of the chuck and do some damage, I decided this wasn't the smartest approach, and made a proper jig to hold the pulley in the lathe.
I also tried doing this on a milling machine, but never had satisfactory results. Prob just me, I'm sire someone can do it.
I've even considered cutting away most of the metal with an abrasive wheel or carbide burr. Both would be pretty noisy and messy, so I didn't.
Thanks to Dave for coming up with this mod and handling the sales!
-Armen

Banzai:

Pulley shipped.

Now only 4 left.

Dave

Yep, I currently have 2 kits all packed up and ready to ship.

So, when I was still at the shop with a big honking South Bend lathe, I'd just grab the pulley in a 3-jaw chuck and spin away. Did a bunch that way, until one day I took too big a bite and the pulley went sailing. Luckily, no damage or death done.
Dug around and found some aluminum scrap and made a simple jig to hold the Kawasaki pulley. Made match marks, and notes as to the offset/depth desired. Made a few more with the jig.
So, now comes the time to try it on my much smaller home lathe. Happy to say, it worked out just fine. i had found a dirty-but-happy Kawi pulley on eBay, and set it up. Only tough part is cutting near the splines as they are hardened. Indexible carbide insert cutters and the appropriate amount of foul language, and all is done!
So, the good news is that the pulleys will still be produced. Talk to Dave as he has the whole kit of hardware and such.
thanks,
-Armen

Awesome! Thanks for the hint! I'll look for some.

Hey Sir,

I'd like to order a front pulley if you have any in stock.

What is the best way to get you the cash?

Thanks in advance,
-Pete

Mrpete:

I have one in stock, packed in a box, and ready to ship.

I have sent you a personal message with my email address: