SuzukiSavage.com - The Project: Phase 4

Gyrobob

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Re: The Project: Phase 4
Reply #75 - 10/17/11 at 13:40:19

MotoBuddha wrote on 10/16/11 at 10:46:53:

Like others, I was having trouble getting the air filter to fit. Then I watched the Ryca video on the matter and understood what I needed to do. I got it on, but the filter was tilted downward a bit. After rechecking things I saw part of the frame crossmember was bent. So I straightened it and everything fit fine.

http://i280.photobucket.com/albums/kk182/motobuddha/d25d1d5f.jpg

However, I don't know that I like the top of the filter touching the crossmember. Vibrations can make it do unwanted things. So I'm going to try bending the crossmember upward some more to see if I can get a little clearance.

On both our bikes, even peening that cross piece above level didn't make enough room. The carb is still not true in the mount on the cylinder.

Also, there is a clearance problem with the tank hold-down screwheads and the air filter.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: The Project: Phase 4 Reply #76 - 10/17/11 at 13:52:27 Maybe getting a wedge shaped spacer made to tilt the carb down a bit is a decent answer?
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MotoBuddha

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Charlotte, NC

Re: The Project: Phase 4
Reply #77 - 10/17/11 at 15:05:22

Since my bike originally had buckhorn bars, I need to have shorter cables made up. It took me a while to figure out how much to shorten each cable, what with the fittings, elbows and such. But then it hit me.

-- Attach one end of a cable in place, route it where it needs to go, with the bars turned all the way to the position that would require the most length -- bars turned to the left for the clutch and speedo, to the right for the throttle.

-- Choose a reference point on the chassis, like a bolt, and mark the cable.

-- Unattach the end you had attached and attach the other end, routing the cable the same way. Mark the cable again, using the same reference point. The distance between the two marks is how much shorter the new cable needs to be.

Now that I have that figured out, I'll be sending the two old cables and the way-too-long new Ryca speedo cable off to Motion Pro to have new ones made.

http://www.motionpro.com/motorcycle/custom/

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MotoBuddha

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Re: The Project: Phase 4
Reply #78 - 10/18/11 at 12:53:13

I'm not the most organized guy. I had put parts for this bike in several places -- places that made perfect sense at the time. That means I've spent a lot of time lately searching all those places for odd parts.

The latest quest was the cable that activates the rear switch for the brake light. I finally found it in a drawer I'd looked in three or four times before -- a large drawer that had only four items in it. It was like I had a malfunctioning part of my brain that saw the cable but didn't recognize it. Man, getting old sucks.

Then I tried to remember how the cable mounted. I knew the end near the switch had to attach to something. Had I cut that tab off when I was in a tab cutting frenzy? That wouldn't be good. I finally located it with my fingers. Ah, good. But the cable was a filthy mess, like so many of the things on this bike were. And the cable didn't move smoothly in the sleeve. So now it's soaking in Berryman's.

Once that's done, the trick will be to see if I can route it a better way than the standard Ryca way.

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #79 - 10/18/11 at 14:39:43 Ooooo, look what the brown truck brought! Welcome to the 21st Century.
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teabowl13 Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 535	Re: The Project: Phase 4 Reply #80 - 10/18/11 at 15:25:57 " It was like I had a malfunctioning part of my brain that saw the cable but didn't recognize it." My wife calls this MALE REFRIGERATOR BLINDNESS. According to her it applies all over the house...
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #81 - 10/19/11 at 17:48:33 I got some of these to have a little fun with. If nothing else it's fun to say Dzus.
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Serowbot

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OK.... so what's the
speed of dark?

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Tucson Az
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Re: The Project: Phase 4
Reply #82 - 10/19/11 at 18:38:54

MotoBuddha wrote on 10/19/11 at 17:48:33:

I got some of these to have a little fun with. If nothing else it's fun to say Dzus.

http://i280.photobucket.com/albums/kk182/motobuddha/d89a0dad.jpg

What Dzus they do?... Huh

...
Where Dzus they go?... Huh

...
Why Dzus you need them.. Huh

...

I think I Dzus want some too... Huh

...
Dzus they cost a lot?... Huh

...

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Ludicrous Speed !... ... Huh

...

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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: The Project: Phase 4 Reply #83 - 10/19/11 at 19:51:15 I knew a guy who pronounced the name of these fasteners as if it rhymed with "Jesus." He also had a Bye - ant - chee shotgun.
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MotoBuddha

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Charlotte, NC

Re: The Project: Phase 4
Reply #84 - 10/19/11 at 20:41:55

Serowbot wrote on 10/19/11 at 18:38:54:

MotoBuddha wrote on 10/19/11 at 17:48:33:

I got some of these to have a little fun with. If nothing else it's fun to say Dzus.

http://i280.photobucket.com/albums/kk182/motobuddha/d89a0dad.jpg

What Dzus they do?... Huh

...
Where Dzus they go?... Huh

...
Why Dzus you need them.. Huh

...

I think I Dzus want some too... Huh

...
Dzus they cost a lot?... Huh

...

I'm going to do something I hope will be unique, so I'm not going to tell you. Neener neener neener.

I got a 10-pack of them, including the back springs, for about $15.00 from Summit Racing.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 29692 Tucson Az Gender:	Re: The Project: Phase 4 Reply #85 - 10/19/11 at 22:18:53 Arrrrghhhh!.... @*@?@%#$$&!!!!!... Hurry up and get that thing together!... ...
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: The Project: Phase 4 Reply #86 - 10/20/11 at 04:59:13 Gyrobob wrote on 10/19/11 at 19:51:15: I knew a guy who pronounced the name of these fasteners as if it rhymed with "Jesus." What Would Dzus Do?
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Gyrobob Serious Thumper Offline Posers ain't motorcyclists Posts: 2571 Newnan, GA Gender:	Re: The Project: Phase 4 Reply #87 - 10/20/11 at 08:10:04 MotoBuddha wrote on 10/20/11 at 04:59:13: Gyrobob wrote on 10/19/11 at 19:51:15: I knew a guy who pronounced the name of these fasteners as if it rhymed with "Jesus." What Would Dzus Do? He would clamp down hard and hold everything together. His one problem, though, is money. He could be undone by a dime.
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MotoBuddha

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Re: The Project: Phase 4
Reply #88 - 10/20/11 at 09:31:58

As you can see, I started cutting up the battery box and frame (wish I had something other than an angle grinder) in order to get the air filter to sit properly. I thought I had it close enough to the correct position the other day after bending up part of the cross piece, but the carb wasn't completely seated in the intake boot.

So first I cut off the part of the crosspiece I'd bent up. That didn't help. It was hitting the battery box. So I cut back part of the box. That's when I saw the filter might be hitting the bolts. Some button head bolts would gain me a wee bit more, but not enough. (There are short screws in the photo, because I got tired of removing and replacing the long ones.)

The filter was still angled like this.

So I've decided to scrap the filter and try this cone shaped one.

http://www.knfilters.com/search/product.aspx?Prod=RC-1250

I was hoping K&N had a suitable size with an angled flange, but no.

Again, since I'm using a compact lithium battery, I'll have room for the end of the filter. If I need to, I'll move the rectifier elsewhere, like the inside back of the battery box.

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LANCER

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Savage Beast
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Oklahoma
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Re: The Project: Phase 4
Reply #89 - 10/20/11 at 10:46:12

MotoBuddha wrote on 10/19/11 at 17:48:33:

I got some of these to have a little fun with. If nothing else it's fun to say Dzus.

http://i280.photobucket.com/albums/kk182/motobuddha/d89a0dad.jpg

Aren't they perty ? Oh yea.
They have been used on aircraft for lots of years
They make installing and removing sheet metal or small parts EASY
and when locked they are extremely secure.
I love em.
I had a source for them in wholesale quanties a year or two ago but not sure now.
Does RYCA use them ? I don't remember right off hand.

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