SuzukiSavage.com - 1987 Savage Street Tracker build

TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #840 - 06/26/23 at 14:41:48 I haven't played with clay for something like 60 years! This is the Exhaust side. Plenty of piston to valve clearance.
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springman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2191 Spring, Texas Gender:	Re: 1987 Savage Street Tracker build Reply #841 - 06/26/23 at 14:41:59 That is impressive. Looks beautiful. I wish I had that skill set!
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #842 - 06/26/23 at 14:43:34 This is the intake side. Apparently I needed to wipe down the piston better, or use more grease. It's easy to see that there is more piston to valve clearance than the exhaust.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #843 - 06/26/23 at 14:44:33 The deck height is right at the target of .040".
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #844 - 06/26/23 at 14:46:55 Now is time to tear it back down to the block, and start cleaning everything in prep for the final assembly. I still need to finish cleaning the outside of the cam cover, and replace the rockers and shaft seals. More to come in a couple days!
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zevenenergie Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1250 The Netherlands Den Haag	Re: 1987 Savage Street Tracker build Reply #845 - 06/29/23 at 04:28:19 All looks very professional. Bless you.
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DragBikeMike

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Re: 1987 Savage Street Tracker build
Reply #846 - 06/29/23 at 15:42:25

Love what you've done. Thanks for the pics of the clearance checks. Your clays look great. I like the way you only used the inner springs to keep the turning resistance to a minimum.

The head is the cleanest I've ever seen. How did you get that sparkle?

Hope this tip isn't too late. You can put your crankcase in the frame. Remove the cylinder studs and install the cylinder & head. Then insert the cylinder studs and finish assembling the head cover. That way, you won't tear up your beautiful silver powder coating on the frame.

You're correct, your tracker will be a "stunner".

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TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #847 - 06/29/23 at 15:52:58

Not too late for that tip! I got side tracked by a neighbor to try and repair his crappy welds on a roll bar for his hot rod. I asked him to let me help him initially, but he wanted to try and weld it himself. With the wrong equipment. Lots of grinding before any new welds could go down. I am now two days into what would have been a 2 hour job. My shoulders and neck are already sore and it isn't finished.

The cylinder head is freshly ported and painted. The head work was done by Built Motors. The company is owned by one of the machinists from Thumper Racing. Thumper closed, and sold most of the equipment To Kevin, who then opened his company. He did a great job, using some of your measurements and some of his own porting knowledge. I will definitely put the bottom end in the frame first. May be a good time to replace the cylinder studs, anyway.

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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 #848 - 07/01/23 at 14:05:57

Today I disassembled the cam cover. Listen, boys and girls... using the whole tube of silicone is not the answer to an oil leak (or ensuring there won't be one). After an hour of scraping, I have about 95% of the excess removed. It was squeezed into every hole and cavity. Even into the cam area. I have never seen this abuse of a sealer this bad before. If you have to use more than a thin (THIN!) layer, something else is wrong. I finally have this part ready for chemical cleaning. The top will get the same satin black engine paint.

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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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Ruttly Serious Thumper Offline Thumpers Rule Posts: 4997 Manteca , CA Gender:	Re: 1987 Savage Street Tracker build Reply #849 - 07/02/23 at 14:05:17 Sneeze , An abuse of sealant clearly indicates lack of knowledge and/or working experience ! Meaning : they have never had to clean that crap OFF Not just in motorcycles , I’ve seen sealant destroy an engine. It is pleasing to see your misery , everything should be spotless before assembly.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4174 Honolulu	Re: 1987 Savage Street Tracker build Reply #850 - 07/03/23 at 01:03:20 One of these makes sealant application a breeze. Perfect, exceedingly thin layer of sealant every time. Works like a paint roller. Super cheap and easy to make.
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DragBikeMike

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Re: 1987 Savage Street Tracker build
Reply #851 - 07/03/23 at 01:10:52

This old post provides the specifics. BTW, I love the Permatex Optimum Grey and Optimum Black sealants. They are both very easy to remove after they have been in service. The grey is a bit easier to remove than the black, but both are very easy to apply and work great. The black just sticks a bit better than the grey. Good stuff.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1525551307

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Ruttly

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Re: 1987 Savage Street Tracker build
Reply #852 - 07/06/23 at 11:28:32

DBM, Have you ever used Permatex gasket eliminator , grape jelly stuff ? It’s an anaerobic purple jelly. Just don’t get it in the aluminum thread holes. Being anaerobic once the bolt has pulled some into threads it becomes loctite.. I always want to use it on just the main case halves but I’ve been using that 3M yamabond forever , maybe next engine ! It $$ too , I could send you a tube to try if you want , great stuff just remember what you’re working with. It’s good for small/tiny stuff as well as giant equipment. Have never had a leak , against gear oil , motor oil , hydraulic fluid , coolant it’s an awesome sealant. It also fills very small gaps and imperfections.

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« Last Edit: 07/07/23 at 11:53:58 by Ruttly »

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TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #853 - 07/12/23 at 13:10:10

To measure my deck height and valve to piston clearance, I had to have a cylinder base gasket installed. I had inadvertently thrown out the old one when I disassembled this motor. I had to use my new one. I believe it is a factory gasket, and comes with a bead of sealant around the perimeter. By installing it, I figured it would no longer be useable after removing the cylinder. I was a bit surprised when I took the cylinder off. I guess the sealant must be too old and no longer pliant. It doesn't seem it would seal very well when torqued. Anyone else see this sealant condition upon disassembly? Shocked

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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: 1987 Savage Street Tracker build Reply #854 - 07/12/23 at 13:10:44 Another view
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