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General Category >> Rubber Side Down! >> Model Years and Part Compatibility
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Message started by jjthejetplane on 06/06/18 at 12:34:39

Title: Model Years and Part Compatibility
Post by jjthejetplane on 06/06/18 at 12:34:39

Hi,

It’s been a while and my searching skills have fallen to the wayside. I am curious to know if parts from all model years will work for all Savage/s40 bikes.

I am looking for a complete clutch assembly for an 01 Savage. I know the years preceding should work but what about the later models? I’m shopping on eBay/ salvage yards bc I don’t want to spend a ton but I am trying to be as conscious/cautious as possible.

Thanks,

The Jet

Title: Re: Model Years and Part Compatibility
Post by verslagen1 on 06/06/18 at 12:56:12

If you're talking about the clutch basket and the gear on the back, only the 1st year maybe the second (86, 87) may not work in other years. But would work if you got the matching primary gear... I think.

All other clutch parts are more or less the same throughout the years.

Title: Re: Model Years and Part Compatibility
Post by Fast 650 on 06/08/18 at 11:05:20

That could be an option for those seeking taller gearing. The higher primary ratio could be combined with the Kawasaki pulley(s) to go even higher.

Title: Re: Model Years and Part Compatibility
Post by DragBikeMike on 06/08/18 at 17:44:29

That is one excellent observation Fast. Does anyone have the tooth count for the older gear set? What parts must be changed to do the conversion?

Title: Re: Model Years and Part Compatibility
Post by Fast 650 on 06/09/18 at 11:49:57

There is a picture in the companion cd that lists the ratio of the early primary set. But, like the pulley swaps, it will throw the speedometer reading off if you try it.

Title: Re: Model Years and Part Compatibility
Post by DragBikeMike on 06/09/18 at 12:52:42

Isn’t it a bit easier and cleaner to swap out the basket and primary drive gear? You don’t have to modify anything or grind away case material for clearance (irreversible). If you wanna put it back like it started just swap the old parts back in. The stock pulley is also lighter than the larger Kawasaki unit so there are less inertial forces working on those already precarious splines.

Title: Re: Model Years and Part Compatibility
Post by DragBikeMike on 06/09/18 at 13:05:37

Isn’t it a bit easier to change out the basket and primary gears than change the pulley? You don’t have to machine the hard pulley or grind cases for clearance (irreversible). If you wanna put it back like it was just swap in the old parts. Plus you also have the option of combining the two mods for even taller final ratio. The Kaw pulley is also heavier so it creates even more of an inertial problem on those already precarious splines.

I think you got a winner idea Fast. The speedo is toast either way so it’s a wash.

Title: Re: Model Years and Part Compatibility
Post by batman on 06/11/18 at 08:33:53

The swap your talking about would change the primary drive ratio from 1.888 to 1.811 (36/68 to 37/67) about 4.1% or about half what the front Kawa pulley will do 9.2%. But they could be used in combination. Assuming 4010 rpm to be 60 mph (stock) the combo would reduce rpm to 3530 @ 60 mph ,with a stock 140/80/15 tire.

Title: Re: Model Years and Part Compatibility
Post by DragBikeMike on 06/11/18 at 13:10:07

I just returned home from my trip and was looking at the illustrated breakdown of the trans in my totally-accurate way-informative Clymer manual (I love the section on tires where it tells you to change the valve-stem when changing the tire but doesn't mention the tube, or even imply that there is a tube). I noticed that the speedo drive runs off the right side of the output shaft. That means that there would be no affect on the speedo if you only change the basket and primary gears. Do I have that right?

Of course if you mess with the pulleys then you can expect the speedo to be off.

Based on Batman's numbers seems to me like if you did both you would have a pretty nice 5th gear cruiser, right in the sweet spot.

Title: Re: Model Years and Part Compatibility
Post by justin_o_guy2 on 06/11/18 at 13:58:20

course if you mess with the pulleys then you can expect the speedo to be off.

You can expect change.
Most of them are off now.
They report that you're faster than you are usually.

Title: Re: Model Years and Part Compatibility
Post by batman on 06/11/18 at 16:33:32

DBM it appears your correct , just changing the basket and drive gear should not alter the speedometer reading. I looked at Ron Ayers site,and it appears there was no change in the speedo drive gears or speedometer in any years.

Title: Re: Model Years and Part Compatibility
Post by Dave on 06/12/18 at 04:43:09

2D2E3B222E217B774F0 wrote:

The ratio change in the primary gears happens prior to the speedometer drive.....so it has doesn't change the speedometer ratio.

Anything you change after the output shaft (pulleys or tire or wheel size) will affect the speedometer ratio.

Title: Re: Model Years and Part Compatibility
Post by Dave on 06/27/18 at 04:13:32

6D6E7B626E613B370F0 wrote:

It could be that the 1986 ratio was not continued for all 1986 models.....or the eBay sellers are not good at keeping track of the bikes the parts came from.

I have been watching the 1986 clutch basket sales and counting teeth...and so far I have not found any clutch baskets with only 67 teeth. If you do find a 67 tooth clutch basket - be sure to also get the matching crankshaft gear....as those parts are no longer available from Suzuki through their parts list.

Title: Re: Model Years and Part Compatibility
Post by Dave on 10/29/18 at 08:55:37

7C7F6A737F702A261E0 wrote:

Has anybody actually seen a 1986 37 tooth primary and 67 tooth clutch basket assembly? I have been watching eBay, and all the clutch baskets have 68 teeth.....even the ones listed as 86 models.

Title: Re: Model Years and Part Compatibility
Post by LANCER on 10/30/18 at 07:43:44

Does the info on the basket mention anything about being used in other Suzuki models ?
Seems like I saw something once about that.

Title: Re: Model Years and Part Compatibility
Post by Dave on 10/30/18 at 07:50:44

I don't even know the part numbers for the 1986 (37/67) pieces. The online parts lists don't show the part numbers for them - as they are no longer available from Suzuki.

Title: Re: Model Years and Part Compatibility
Post by batman on 10/30/18 at 16:11:23

Dave ,it could be that the 37/67 ratio never made it into production even in 86, but this could explain the speedometer error we see in the 5 peed bikes as the speedo drive gear appears to have never been changed and may have been setup for the 37/67 ratio .who knows? If true 60mph on the 86 as designed , would read about 57.55mph on the 5 speed ,less as the rear tire wears.

Title: Re: Model Years and Part Compatibility
Post by Dave on 11/28/18 at 17:21:00

I took the clutch cover off of a 4 speed engine that I believe is a 1986....the serial number is P401-109968.

The engine has a 36 tooth crankshaft sprocket - so it appears that the 37 tooth was not in use when this engine was made.

I can't find the part number listed on any online OEM suppliers - what is the source of the 37/67 tooth data for a 1986 bike? Does someone have a part number for those pieces (I can't find them online).

Title: Re: Model Years and Part Compatibility
Post by batman on 11/28/18 at 20:52:12

Ron Ayers lists the parts , but they list the 36/68 ,I don't think the 37/67 ever made it into production.

Title: Re: Model Years and Part Compatibility
Post by Dave on 11/30/18 at 03:30:12

OK....I think I got this figured out - it is the reverse of what I was thinking.

The 86-95 bikes have the shorter 36/68 ratio (4 speed).

The 96 through current bikes have the taller 37/67 ratio (5 speed).

The 5 speed bikes already have the taller ratio - 4 speed owners could install the later gears if they want to get longer legs for their bikes.

Title: Re: Model Years and Part Compatibility
Post by batman on 12/03/18 at 19:55:29

Dave I believe your correct except for the U.S. 1995 bikes, they have the five speed trans and the newer ratio (I own one) what they don't have is the anti kick back gear for the starter , that came in the 96 model.