SuzukiSavage.com - Retro Thumper project

Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17815 Camp Springs, Kentucky Gender:	Re: Retro Thumper project Reply #165 - 02/06/24 at 17:55:37 This is what the parts look like when they are installed. The rubber cushions push onto the end of the bolt and the washer goes into the recess in the cushion.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4184 Honolulu	Re: Retro Thumper project Reply #166 - 02/07/24 at 23:54:00 Never tried anything like that. Pretty cool. So, you just heated the areas up and then used some sort of forming hammer to tap them into the desired shape? It doesn't affect the outside areas of the tank? Can you post a picture of how it looks when it's on the frame?
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17815 Camp Springs, Kentucky Gender:	Re: Retro Thumper project Reply #167 - 02/20/24 at 15:58:32 I was able to fabricate the rear tank mount today. I made a square pocket to hold a block of rubber that has been sized to fit the cushion mount on the bottom of the tank, and then I bolted a cross bar to it. The bolt will allow me to make adjustment in height if needed.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17815 Camp Springs, Kentucky Gender:	Re: Retro Thumper project Reply #168 - 02/20/24 at 15:59:44 This is what it looks like with the tank in place. The tank will be held down with the original factory strap that hooks into the back of the tank.
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Re: Retro Thumper project
Reply #169 - 02/20/24 at 17:21:27

This is what I do for the front tank mount...

the rubber buttons press onto the ends of 5/16" allen head bolts.

use 1" aluminum rod for the spacers, 1 with a thru hole, the other is threaded for the bolts.
size 1 bolt to go thru the spacer, frame and halfway into the threaded spacer. the other bolt is short, you just need the head to mount the rubber button.

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4184 Honolulu	Re: Retro Thumper project Reply #170 - 02/21/24 at 20:41:56 That is a very slick rear tank mount Dave. I'm lovin that you incorporated an adjustment feature along with resilient mounting.
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2689 WTF is JOG?	Re: Retro Thumper project Reply #171 - 02/22/24 at 18:38:53 How did I miss this a couple of days ago? Weird. Anyway... Looking good Dave. I can't wait to see how it comes together.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Retro Thumper project Reply #172 - 02/23/24 at 05:40:45 That's a great solution on the tank mount.
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Re: Retro Thumper project
Reply #173 - 02/23/24 at 10:33:07

Are you doing a stock engine or one with a bit of spice ? Maybe some knee pads on the tank too , seal in that British look. I’ve been trying to add very subtle British accents without over doing it to the 250. But then again it’s a BSA. I like the creative fabrication for the tank mounting. Very interested in your build , I learn from others as they power thru the problem solving process. Chain or belt ? Can’t wait to see it ! Cool

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Re: Retro Thumper project
Reply #174 - 02/23/24 at 16:07:56

The engine has a 97mm Wiseco pop top (DR650 piston) that has 9.5:1 compression. The head has been ported, DR650 camshaft, Mikuni VM 38mm carb, DR650 clutch mod with an extra steel and fiber plate, Sneezy clutch cam. The goal was to make an nice torquey engine to pull the high gearing and allow for comfortable cruising on the highway.

The final drive will be belt with the Kawasaki EN500 front pulley and KZ750 rear pulley. On my Cafe' bike this provides 3,500 rpm at 60mph and 4,000 rpm at 70mph.

I am not sure yet about the paint scheme and final touches. I do have a set of Givi removable hard sidebags that will be used - so I need to adapt the mounts to this bike (I believe the original owner had an SV650 and that is what the bag mounts are from).

Today I worked on removing a pound of brackets that are no longer needed.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17815 Camp Springs, Kentucky Gender:	Re: Retro Thumper project Reply #175 - 02/23/24 at 16:08:20 Sometimes the best workbench is the lawn!
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17815 Camp Springs, Kentucky Gender:	Re: Retro Thumper project Reply #176 - 02/23/24 at 16:10:00 Armen would be proud of me.....I lightened the load a bit.
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Re: Retro Thumper project
Reply #177 - 02/23/24 at 16:13:56

I had the bike on the ground and checked the fork clearance with the mounted tank - thankfully it clears and I won't need to modify the fork stop as I did on the Cafe' bike (On the Cafe' bike the clip on handlebars got too close to the tank with the stock fork stops and I had to reduce the travel a small amount).

I am at a bit of a stopping point on the bodywork, footpegs and rear fender until the seat arrives from Vietnam. I will put an engine in the frame and start working on the wiring, battery mount, engine breather, air cleaner and handlebar controls.

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 4997 Manteca , CA Gender:	Re: Retro Thumper project Reply #178 - 02/23/24 at 17:28:38 That will silence the critics ! Looks good Dave
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10603 Oklahoma Gender:	Re: Retro Thumper project Reply #179 - 02/23/24 at 19:13:32 What’s the seat like that’s coming from Vietnam ?
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