SuzukiSavage.com - 1987 Savage Street Tracker build

DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: 1986 Savage Street Tracker build Reply #405 - 01/20/22 at 13:18:52 This is your #5.5 slide in the same carb body. You can see there is more light getting through, indicating a larger gap. You should be able use a feeler gage to survey the whole arc across the outlet side. That might uncover some blemish that is causing the bind.
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DragBikeMike

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Re: 1986 Savage Street Tracker build
Reply #406 - 01/20/22 at 13:19:41

The two dimensions you should be concerned with are the width (nominally 1.600”) and dimension “A” shown on this markup. I measured “A” at .446” on my #7.0 and .435” on your #5.5. I never measured the #7.0 slide I sent to you (except for the cutaway). The width on your old #5.5 slide is 1.596” and the width on the #7.0 is 1.607”. There are big variations in dimensions.

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: 1986 Savage Street Tracker build Reply #407 - 01/20/22 at 13:20:24 I measured dimension “A” using a surface plate, 123 blocks, and a dial indicator. I set the zero reference using my known-good #7.0 slide.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: 1986 Savage Street Tracker build Reply #408 - 01/20/22 at 13:21:05 The #5,5 slide you sent me read -.011”.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: 1986 Savage Street Tracker build Reply #409 - 01/20/22 at 13:21:52 Then I stacked a .375 tool bit and some feeler gages to return the indicator to zero.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: 1986 Savage Street Tracker build Reply #410 - 01/20/22 at 13:22:25 And double checked the stack with a micrometer. So, I know the #7.0 is .446”and the #5.5 is .435” (.446 - .011 = .435). The #7.0 works fine in my PWK36 and also my pseudo PWK40. Your old #5.5 also goes in & out of my PWK36 just fine.
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DragBikeMike

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Re: 1986 Savage Street Tracker build
Reply #411 - 01/20/22 at 13:23:45

Here’s a suggestion that might help you determine where the bind is. Clean your slide with a good solvent and then apply a very light coat of flat-black primer. Let the primer dry and then carefully insert the slide into the carb body. The primer should rub away wherever the slide makes hard contact. Let us know what you find.

Looks like your valve stem tips came out sweet.

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TheSneeze

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Re: 1986 Savage Street Tracker build
Reply #412 - 01/20/22 at 13:42:53

Of all my tools, measuring equipment I am sorely short of. Funny as I ran a QA lab at the metal fab shop for 24 years. The slide is binding across the entire length of the large radius. Not gap or light at all. I will try to set up your measurement as accurately as my tools allow and let you know what I find.

This is the "I'm stuck!" position.

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20220120_1338381.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 Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #413 - 01/20/22 at 13:43:49 "light" view with sunlight backing. No visible light traces.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #414 - 01/20/22 at 13:57:17 First I zero'ed my drop indicator on the flat bar. Yes, the sheet metal was cleaned under the flat bar, and no burrs on the flat bar either.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #415 - 01/20/22 at 13:58:10 Here is the apex measurement of the nice plating DBM #7 slide. .445"
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TheSneeze

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Re: 1986 Savage Street Tracker build
Reply #416 - 01/20/22 at 14:01:42

Here is the apex measurement of the crappy plating #7 slide that came with the carb (it slides up and down smoothly). .440"

My only conclusion is the .005" difference in thickness is what causes the bind. I took some 340 grit sand paper to the support "runner" in the carb, but it will take a much more aggressive grit paper to remove even .003-.004" of metal. What I did really had no affect.

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20220120_1353491.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 Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #417 - 01/20/22 at 14:07:26 Here you can just make out a shiny rub mark in the center of the support rib where I had sanded. There are no visible marks on the slide surfaces.
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DragBikeMike

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Re: 1986 Savage Street Tracker build
Reply #418 - 01/20/22 at 16:35:57

I would stay away from that downstream side of the carb body (the arced side). If you want to remove metal, take it off the upstream side, the two straight sections adjacent to the bore. Does your bore have that large gap as shown in my picture (the .09" gap, reply #402)?

You have some options.

1. Use the ugly slide. It goes up & down. It has a #7.0 cutaway. Just cause its ugly doesn't mean it won't work.

2. Lap the carb body with a slide. Use coarse grit to speed metal removal. Only apply the lapping compound to the flat runners on the upstream side of the slide. If you have no interest in using the ugly slide, and want to preserve the good 7.0 slide, use the ugly slide for a lapping tool.

I don't think you have much to remove. It shouldn't take too much effort. Your investment is low, so your risk is low.

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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #419 - 01/20/22 at 20:35:53 I am going to go with option #1. I have taken some very fine sandpaper and knocked the top of the plating "pimples" off, just to make sure it is not acting like a file so much on the inside of the carb. Let me know what you find out with that #5.5 slide. It will be interesting (as always) to read your findings.
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