SuzukiSavage.com - 1987 Savage Street Tracker build

TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #435 - 01/23/22 at 14:24:24 Now I can sleep at night!
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #436 - 01/23/22 at 14:25:59 The trick with this modification was to get the new washer bigger than the spacer OD, but smaller than the threads on the inside of the fork tube, so the washer movement wouldn't damage the threads when adding preload.
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Edub Full Member Offline SuzukiSavage.com Rocks! Posts: 160 Arizona Gender:	Re: 1986 Savage Street Tracker build Reply #437 - 01/23/22 at 15:38:16 Nice work, TheSneeze! How long did that little headache take to fix?
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #438 - 01/23/22 at 16:14:01 A couple hours fiddling around, test fitting, grinding some more... it's just shop time to me. It's my happy place.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #439 - 01/23/22 at 16:51:27 This is with the adjusters at the lowest preload setting.
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Edub Full Member Offline SuzukiSavage.com Rocks! Posts: 160 Arizona Gender:	Re: 1986 Savage Street Tracker build Reply #440 - 01/24/22 at 05:33:26 TheSneeze wrote on 01/23/22 at 16:14:01: A couple hours fiddling around, test fitting, grinding some more... it's just shop time to me. It's my happy place. Totally understand, it’s my happy place too, when I have the opportunity to make things. Doesn’t happen enough in my garage, though.
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TheSneeze

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Re: 1986 Savage Street Tracker build
Reply #441 - 01/24/22 at 13:40:06

I got my used DR650 clutch basket in the post today. After seeing comparison pictures of the LS hub and DR hub next to each other, I assumed the baskets would be a different height to accommodate the extra plates. I am wrong in thinking this? One of things I hate buying off of Fleabay - how do you know you got the right part? Here are comparison photos of what is supposed to be a 1993 DR650 clutch basket next to the stock 1987 LS one. LS is on the left, DR on the right in all three of these pictures.

Appears to be the same height.

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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 Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #442 - 01/24/22 at 13:41:02 top view. The DR unit clearly has more rivets.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1986 Savage Street Tracker build Reply #443 - 01/24/22 at 13:42:46 bottom view. No springs. So can any of you that have done this clutch mod ease my worried mind? Is it only the DR hub that is taller and the baskets are the same height for both models?
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badwolf Serious Thumper Offline Ridin' my Lil' Bagger - 153k miles so far Posts: 793 Palm Beach County, FL Gender:	Re: 1987 Savage Street Tracker build Reply #444 - 01/24/22 at 16:11:32 Are you SURE this is a direct swap? The oil pump drive gear is way smaller, and does not look like it will swap. ???
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #445 - 01/24/22 at 16:21:26 1) I am not sure I got what I ordered. 2) After re-reading the beef up the clutch thread, I may have misunderstood that the DR clutch basket was needed as well. I may have paid for a part I don't need.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4207 Honolulu	Re: 1987 Savage Street Tracker build Reply #446 - 01/24/22 at 18:43:27 Yes, you paid for a part you didn’t need. You only need the hub. The pressure disc is nice to have but you can bore out the LS pressure disc to suit the DR hub. See my reply to your post on the beefed up clutch for info on the pressure disc machining.
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TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #447 - 01/25/22 at 07:43:37

Isn't the first time I have wasted money on something I couldn't use for this project, and more than likely won't be the last, either. Oh well. You have to break a few eggs to make a nice omelet.

I am heading out to the machine shop today to modify more parts. I am interested in finding out the cost. I will post the info when I get the quote.

Side cover - remove material and deepen shaft hole for wider starter gear

Clutch actuator plate - deepen spring seats

Clutch pressure plate - open hole for DR650 hub clearance

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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: 1987 Savage Street Tracker build
Reply #448 - 01/25/22 at 11:05:01

Out of the three parts to modify, the side cover is the most complicated, set up wise. The machine shop labor rate is $95/hr. He estimated at least an hour of set up alone on the side cover. That being said, he told me all the parts should be under 3 hours labor, so less than $300. We will see where the labor ends up in a few days.

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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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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2626 Amongst the Twisty Roads	Re: 1987 Savage Street Tracker build Reply #449 - 01/25/22 at 14:09:12 Have your side panels printed. Do you have a CAD program?
Back to top	A life-time student of motorcycling. LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG IP Logged