SuzukiSavage.com - Gentlemen Behold: Dual Disc Front End for LS650

philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #45 - 08/26/19 at 08:22:55

Reviewing the parts diagrams there's the discrepancy with the gear for the speedo drive in my wheel. The one I have is different looking from the drawing. For some reason its probably the wrong part and the gear is stopping the drive from seating all the way into the hub.
That would explain the 1/8" offset.
For all I know the wheel or the gear came from a Ninja or one of the other models with similar parts.

I'm not gonna try and figure it out. I've got better uses for my time. I'll just go the custum spacer route and call it a day...

I don't need the drive and it probably won't work with the Savage speedometer anyway.

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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Fast 650 Senior Member Offline SuzukiSavage.com Rocks! Posts: 396 Valrico, FL Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #46 - 08/26/19 at 09:21:20 That is from about the time when all of the Japanese makes standardized the speedometer ratio. I don't recall what year that happened but if it was after that point then any speedometer would read correctly with that drive.
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SpamyToo Full Member Offline Posts: 233	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #47 - 08/26/19 at 09:34:43 Page 58 of the parts manual shows it looking like this. You can download the manuals from my site if you want. Some of them are pretty large though. The service manual may not be completely uploaded yet. I have a ton of manuals here and there. https://dcmotive.com/manuals
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #48 - 08/26/19 at 11:17:37

Fast 650 wrote on 08/26/19 at 09:21:20:

That is from about the time when all of the Japanese makes standardized the speedometer ratio. I don't recall what year that happened but if it was after that point then any speedometer would read correctly with that drive.

Interesting. I did not know this. Considering Suzuki made up their own proprietary spinoff of the CAN-BUS protocol on their modern bikes I have to wonder about their adherence to standards over the years. Roll Eyes

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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #49 - 08/26/19 at 11:20:32

SpamyToo wrote on 08/26/19 at 09:34:43:

Page 58 of the parts manual shows it looking like this.

You can download the manuals from my site if you want. Some of them are pretty large though. The service manual may not be completely uploaded yet.

I have a ton of manuals here and there.
https://dcmotive.com/manuals

My 41064 has 4 "teeth" instead of the 2 shown in that drawing. Kinda fishy me thinks.

I certainly love free manuals. Muchas Gracias Señor! Cool

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #50 - 08/26/19 at 16:48:11 Ok ordered 15mm axle stock. Hey and my service manual came in the mail today! It came from Greece. No wonder the long wait...
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #51 - 08/26/19 at 18:25:30

The manual confirms my suspicion. It says line up the drive housing so that the teeth in the gear line up with and fit into the two slots inside the housing. Under a bright light I can see inside the housing and there's two slots. My gear has 4 teeth so it can't fit all the way into the housing since 2 of those teeth Don't have corresponding slots.

Sooooo, custom spacer. I'm not hunting down another elusive part.

On the bright side I now have torque values for all the nuts and bolts and the procedure for replacing the fork oil. This last is good since I've found at least 4 totally conflicting forum posts on the amount of oil to put in around the web Angry

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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #52 - 08/28/19 at 16:41:32

Picked up some retention ring pliers for taking the fork caps off and used them to remove the speedo drive gear from the wheel. Turns out that the gear doesn't have 4 teeth it has 2 like it's supposed to. But its damaged in such a way that it looks like 4 teeth. Bent the damaged parts back the right way and sure enough it fits all the way in now.
And the spacer stock came today. Go figure.

I also managed to free up the frozen caliper I was grouching about before. The rubber condom that goes over the slider pin got bound up inside the tube. Folded over itself from lack of lubrication I guess. I've had that happen to me too and it's not pleasant. Anyway put my rubber mallet to good use and now I have the bracket free which I need for new calipers which have the wrong brackets.

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #53 - 09/01/19 at 11:43:06 DIY wheel spacer done.
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #54 - 09/01/19 at 12:56:15 Perfect fit!
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4222 Honolulu	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #55 - 09/01/19 at 18:16:01 That spacer looks total pro. How did you make it? I think you are gonna have a handful of brakes when you are finished with this project.
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #56 - 09/01/19 at 18:39:22

Thanks it's my 1st ever. I hacksawed the stock 2mm longer than needed and squared off and shortened using a combo belt/disk sander real careful like until I had it a hair longer than 39mm. That being the width of the speedo drive. I put the factory cut side of the spacer on the bearing side in case the cut end wasn't a perfect square.

As for the brakes they're single piston calipers and I don't expect they'll be any worse than the massive brembos on my Ducati. I've ridden that bike with ABS turned off and yes it's alot of brakes but still manageable if you are mindful.

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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #57 - 09/02/19 at 12:46:11

Decisions, decisions. The ZL900 Eliminator has a long chrome front brake crossover tube mounted right on the front of the lower triple clamp. See picture.
To use that big crackpipe on the Savage mounting holes need to be drilled into the front of the triple clamp. There's really nowhere else to mount it.

Or I can go with a 2 line setup like seen here...
https://galferusa.com/products/lines

What to do?
2-line setup is expensive and routing the lines might require some imagination.
Crackpipe setup is cheaper since I have all necessary parts but does require making accurately spaced holes in the clamp.

Hmmmmmmm.... Undecided

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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SpamyToo

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #58 - 09/02/19 at 18:55:52

Some lines from other bikes might be easier to mount the tee. But will still take some monkeying.

The Boulevard lines look simpler.

https://www.ebay.com/itm/2006-2007-2008-2009-SUZUKI-VZR1800-M109-Boulevard-FR...

https://www.ebay.com/itm/2013-suzuki-boulevard-OEM-FRONT-BRAKE-CALIPER-HOSES-...

https://www.ebay.com/itm/SUZUKI-BOULEVARD-M109R-2006-08-10-12-2014-FRONT-BRAK...

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #59 - 09/03/19 at 11:37:23 Actually after mocking up my new risers and handlebars it's looking like I'll need a custom solution for brake lines. The required lengths have changed.
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