Christof13T
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SuzukiSavage.com Rocks!
Posts: 211
Vicoria, Texas
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So I have been a little busy getting ready for the jug and new piston to come back from Bill at Bore-Tech.com with a few mild appearance modifications.
Stock saddle, turn signals, airbox, rear pegs, rear signal bracket arms, and about 10lbs of the rear fender are gone.
Replaced the seat with a solo coil sprung bobber pad. Replaced the signals with some very small profile black smoked bullets. Got a base coat of satin black on everything that will get rhino lined... She looks really good in black and high gloss polished aluminum...
I spent a good 20 hours at the bench buffer with jewelers rouge with the engine covers, front drive pulley cover, exhaust heat shield, rear brake housing plate(too lazy to look up the correct nomenclature at the moment lol).
Mounting the solo seat was as easy as chopping the stock seat bolt brackets off the frame and welding in some gussets I made from some 1" flat stock. Drilled a hole in each gusset for a hex head bolt to fit into from inside and sticking out the bottom of the spring... wingnut on the other side of the gusset that backs against the rear fender... very difficult to get to so I don't have to worry about drunk bums trying to steal souvenirs in the middle of the night lol.
Airbox was replaced with a RYCA pancake style chrome flavored filter. Seems to be worth the 25$ or so I paid for it.
I went with a 6Sigma jet kit for 45$ or so and am not impressed. It came with 2 main jets and one secondary... the teflon spacer included did not even fit my needle... the i.d. is too tight. I figured I would give them a chance and review my experiences with their kit here with you fine fellows for critique.
The head is ported and polished... A whole lot of meat can come out of that exhaust port! Just dont overdo it... Your just looking for a smooth transition out of the ports, into the collector... and out into the manifold/header. I know this won't do diddly squat for real numbers until I ditch the stock pipe... But it's what I got for now.
I went with a little conservative finesse while chopping the rear fender. I wanted to lose some of that ridiculous weight and length while still maintaining the ability to hang bags from somewhere. I'm really looking at a pair of 20mm ammo cans for that job. I drew my mock up lines with welding layout chalk freehand... and cut it with a 4" harbor freight angle grinder with a cut off wheel. Deburred, contoured, smoothed and finished the lines with a harbor freight 4" flapper disk on the same angle grinder. Gave the paint a good scuff, hit it with the acetone... and rattle canned it with krylon.
Remounting the tail light was a matter of using the rubber cushion as a template and drilling 4 holes in the fender. There was already a hole present for the rearmost tail light mounting screw but needed the other 2, and a hole to feed the tail light pigtail through the fender. The 4th hole was for the tail light and turn signal pigtails to run back through the other side. There was a perfect pilot hole already there for locating.
The front turn signal mounting clamps were badly... Badly coroded. Almost beyond the help of a wire wheel, let alone a polishing buffer... so I got them as smooth as I could (after pulling the forks and removing them of course) and bathed them in blackness. The new signals fit in place like they were custom fabricated to do so. I still need to rob the connectors off the front signals to keep the bike side wiring harness as factory as I can... But everything is so far happily going back together. Much happier than disassembly! lol
Some more pictures should follow.
This first image is where I am with it as of right now.
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