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1987 Savage Street Tracker build (Read 7061 times)
TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #390 - 01/10/22 at 15:43:09
 
I have always preferred to practice the K.I.S.S. principle.  Keep It Simple Stupid.  An easy way to help fixture the tab for measuring. A steel rod that fits close with the thread ID will help keep things symmetrical. The tab will get tacked in place, then the alignment marks will be cleaned off prior to final welding.
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20220110_1537391.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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Edub
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Re: 1986 Savage Street Tracker build
Reply #391 - 01/10/22 at 21:59:55
 
Great tip using the rod like that, thanks for sharing!
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #392 - 01/17/22 at 12:10:16
 
I have been traveling for the last week, so not much progress.  But it's time to get after the cylinder head.  After masking off the stems I set about bead blasting the carbon off.  After a nice cleaning with 80 grit glass bead, they look like they are in good shape.  I have to get the ends ground at the engine shop, but other than that I think a relap in the seats should do the trick instead of having the seats reground.
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20220117_1204531.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #393 - 01/17/22 at 12:17:50
 
I am hoping the ends can be ground to a minimum clean up and still be within spec. The two intake valves are showing the most pitting.  It isn't very expensive to have the ends ground, so I will measure them after the end clean up and see if any have to be replaced.
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20220117_1211481.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #394 - 01/17/22 at 12:18:38
 
the rear ones from the last pic
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20220117_1212071.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #395 - 01/17/22 at 14:22:10
 
I just got back from dropping the head off at the machine shop.  He will use the stock valves if he can, if not Kibblewhite valves a new guides will be installed.  I am having him do the porting for me.  I provided all the measurements and sketches that DragBikeMike posted on his hotrod thread.  As soon as the 94mm flat top piston arrives (should be soon) he will hone the cylinder to match the piston, and gap the rings.  Sounds like I need to get my mid controls finished soon as the motor will be getting all the attention pretty quickly.
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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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DragBikeMike
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Re: 1986 Savage Street Tracker build
Reply #396 - 01/17/22 at 15:34:33
 
Bonanza.  Those valves are hard to come by.  You have reduced diameter stems.  I have a set of those in a head I bought off eBay.  You have a 1986 model; do I have that correct?  The newer valves don't incorporate that feature.  The intake port flowed 4% better and aside from the port being a bit cleaner, the valves were the only significant difference that I could perceive.

I have no idea how thick the case-hardened shell is.  Does your machine shop have some rule of thumb they use for resurfacing the tips?

You will be running the Mac header so you can take that exhaust port all the way out to 1.79".
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #397 - 01/17/22 at 15:56:17
 
After I started my thread, I found out by deciphering the VIN that this bike is an '87, not an '86.  Doesn't make much difference, though.

Not sure if the Kibblewhite valves are available, or needed yet.  He will measure everything and let me know.  If we can use the originals, that will be the preference to keep costs down.  This shop specializes in single cylinder four stroke engines - mainly dirt bikes.  But he has more experience porting heads than I do.  That translates into better odds of success than me trying it for the first time.  The head will get blasted, then ultrasonic cleaned.  Should be purdy when done.

To resurface the ends of the valves you have to stay within the factory length tolerance.  This is measured from the end of the valve to the nearest edge of the spring keeper groove.  It was an obscure mention in the FSM, but I found it.  No overall length was provided in the FSM.  The stem length is listed in the service specifications at .110", with no tolerance listed.  Section 3-28 of the FSM lists this as the minimum length before replacing the valve.  So we will see if the stem diameters are within spec first, then do a minimum clean up grind and see if the required length is still there.  If Kibblewhite valves are not available, and they need replacing, stock replacements will be used.  I will get the 30 degree back cut done as well.
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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #398 - 01/19/22 at 09:36:03
 
I found out the local engine machine shop that I have used has closed its doors last August.  Bummer.  After much searching, I found the nearest machine shop with the ability to grind valve stems is 45 miles away.  Time for a half day road trip!  I think my truck will consume more gas than the grinding will cost.  Big plus - the guy will do the job while I wait.  Time to find out if they will clean up within spec...
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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #399 - 01/19/22 at 14:28:15
 
All four cleaned up well within the specification.  They are back with the engine shop.
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20220119_1326231.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Re: 1986 Savage Street Tracker build
Reply #400 - 01/19/22 at 14:29:07
 
This is for DragBikeMike (can't attach pics in PM's)
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20220119_1420301.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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TheSneeze
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Posts: 1201
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Re: 1986 Savage Street Tracker build
Reply #401 - 01/19/22 at 15:37:17
 
Just ordered my Superbrace for the front forks.  With Tkat out of the picture there wasn't much choice.  Not running without one.
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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute
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DragBikeMike
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Re: 1986 Savage Street Tracker build
Reply #402 - 01/20/22 at 13:16:07
 
Background: Sneezy received a #5.5 slide in his overhaul kit.  It had some defects in the chrome plating.  I bought a kit to evaluate, and it had the correct #7.0 slide.  It was also in better condition.  We swapped the slides.  When he tried to insert the new 7.0 slide in his carb, it sticks half-way in.

Sneezy, thanks for the sketch.  If you look in the bore of your carb you should see a significant gap between the slide and carb bore (as shown in this pic approx .09").

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Gap_Slide_vs_Body.JPG

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DragBikeMike
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Re: 1986 Savage Street Tracker build
Reply #403 - 01/20/22 at 13:17:12
 
That gap is on my 36mm PWK with your #5.5 slide installed.  I did a rough measurement on the bore in way of the slide and it’s .77”.  I used an inside caliper.
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Slide_Bore__77.JPG

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DragBikeMike
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Re: 1986 Savage Street Tracker build
Reply #404 - 01/20/22 at 13:18:15
 
Check your bore and make sure it’s around .77”.  I’m pretty sure it will be around .77”.   If it is you can ignore the .698/.699 dimension shown on your sketch.

This picture shows the clearance between my 7.0 slide and the outlet side of the slide bore (the large arc).  You can see light coming through.  There is ample clearance.  I realize there is a support pad for the slide that runs up & down the center of the bore, but at the bottom, close to the venturi, it’s a full arc.  So there must be ample clearance down there to permit light to get through.
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Gap_Outlet_Side_My_7_0.jpg

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