SuzukiSavage.com - DRZ Tracker Project

ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2825	Re: DRZ Tracker Project Reply #60 - 05/28/17 at 08:27:15 It's taking a shape nicely.
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Gary_in_NJ

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Re: DRZ Tracker Project
Reply #61 - 05/30/17 at 05:44:23

I was fitting up the exhaust and ran into a minor snag. BTW, that Yosh RS4 is a real fine system - heavy as heck - but does it look pretty. Anyway, I was following the supplied directions when I came across this line:

"install the left and right brackets in the location of the passenger foot pegs"

Passenger what? I don't have passenger foot pegs - nor the brackets to attach said foot pegs (or the exhaust hangars for that matter). More fabrication, grinding and welding.

In the above photo I have the brackets "stuck on" random brackets, but I was able to make some nice "foot peg" brackets out of some spare 0.1875" 2024-T3 aluminum I had.

Having the opportunity to look at the bike, I think I have a solution for the tail section. I've marked the rear fender for trimming and I think I have side panels figured out. As soon as I have the tank/seat/tail bolted down into is final resting place I can build the electronics box under the seat and start wiring this thing up.

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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

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Tocsik Serious Thumper Offline the singularity Posts: 1206 Denver, CO Gender:	Re: DRZ Tracker Project Reply #62 - 05/30/17 at 07:58:32 This is looking soooo nice! Do you have plans for some sort of tire hugger or some way to keep the rear tire from throwing crap all over the monoshock and the rest of that area?
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2642 Amongst the Twisty Roads	Re: DRZ Tracker Project Reply #63 - 05/30/17 at 08:57:29 I may weld some tabs on the swingarm so I can mount an inner fender from a dirtbike.
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

LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10801 Oklahoma Gender:	Re: DRZ Tracker Project Reply #64 - 05/31/17 at 06:08:38 Yep, you need a bit of something in the gapping hole above the rear tire and the bottom of the seat.
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Hamman Ex Member	Re: DRZ Tracker Project Reply #65 - 05/31/17 at 08:49:38 Gary, SUPER COOL BUILD! I want to build a modern, vintage tracker/motard bike in the next few months! This has really lit the fire now. Cannot wait to see the outcome!
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2825	Re: DRZ Tracker Project Reply #66 - 07/12/17 at 09:44:58 Any progress? Are you going to fix the pics? Don't leave us hanging (like Arman does, can someone sneak over there and get some pics?!)
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Gary_in_NJ

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Re: DRZ Tracker Project
Reply #67 - 07/12/17 at 13:25:07

ohiomoto wrote on 07/12/17 at 09:44:58:
Any progress? Are you going to fix the pics? Don't leave us hanging (like Arman does, can someone sneak over there and get some pics?!)

I will fix the pictures, and add more as soon as I find a new web host.

I've been plugging away at the air box and seat under tray. Turns out the Ellasped build just had the air filter stuck on to the boot. That's a solution for photos, not for riding. I've cut up the OEM air box and now I'm integrating the filter hold bar to the under tray. The filter hold bars were part of the sides of the OEM airbox...and I only kept the part where the filter mounts to the boot. It will make sense when I get some photos up

The tank, seat, fender, under tray and side panels all have to work as a system, so a change in one results in a change in some of the others (the tank and seat are fixed...can't move).

Wiring is roughed in, as is the radiator. I'm actually getting close to riding it. I have a few days off in mid-July so I'm quite sure I'll be riding it soon.

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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

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Gary_in_NJ

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Re: DRZ Tracker Project
Reply #68 - 07/19/17 at 06:00:22

I took a few days off to give myself a little staycation. I was hoping to have the DRZ Tracker done, but I think I still need an hour or two of work to get it ride-able. Everything that has to be fabricated has been fabricated. Everything that has to be modified has been modified. The bike has been completely assembled but right now it looks like it has puked-up the wiring harness. The bundle of wires at the front of the bike is just too darn thick - so I've ripped the main harness apart in attempt to reduce its girth. Here are some photo...one at a time.

This first photo is me mocking up the brackets for the new radiator. The original radiators (a split system) wanted to share the same space at the new fuel tank. I decided to ditch the split system and go with a single radiator. Doing some research I found a perfect solution from a Suzuki LTZ400 quad. The nice thing about this solution is that the LTZ400 uses the same engine as the DRZ plus it has 20% more capacity. It took a lot of precise measurements, but it fits. I was able to even reuse the existing radiator hoses with a simple modification.

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IMG_3036.JPG

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

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Gary_in_NJ

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Re: DRZ Tracker Project
Reply #69 - 07/19/17 at 06:06:59

This photo is my under tray that will house the battery, engine ECU, starter solenoid and the rear section of the harness. I bent it out of 0.032 2024-T3. It supports the upper bracket for the air cleaner holder, a rear fender support and the front seat hold down. This little bugger in an integral part of this build. It's very tight on space - so tight that I had to mount the ECU to the bottom of the seat because there just wasn't enough room to squeeze everything onto the surface. With the ECU relocated it's a perfect fit. Once I get the wiring harness sorted out I'll post a photo of how it all fits together.

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IMG_3037.JPG

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

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2642 Amongst the Twisty Roads	Re: DRZ Tracker Project Reply #70 - 07/19/17 at 06:08:35 This photo is the fabrication of the rear tank mount. The front mounts have been welded onto the tank and this mount got welded onto the rear sub-frame.
Back to top	IMG_3038.JPG 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

Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2642 Amongst the Twisty Roads	Re: DRZ Tracker Project Reply #71 - 07/19/17 at 06:09:17 Here it is with the OEM cushions.
Back to top	IMG_3039.JPG 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

Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2642 Amongst the Twisty Roads	Re: DRZ Tracker Project Reply #72 - 07/19/17 at 06:10:34 Here is a photo of what I'm dealing with now. This is the forward harness
Back to top	IMG_3044.JPG 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

Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2642 Amongst the Twisty Roads	Re: DRZ Tracker Project Reply #73 - 07/19/17 at 06:11:03 And here is the rear part of the harness
Back to top	IMG_3045_001.JPG 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

Gary_in_NJ

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Re: DRZ Tracker Project
Reply #74 - 07/19/17 at 06:14:43

And this is what it looked like when I took a dinner break last night. Once I get the harness sorted out, all I have to do is attach the tank and seat - about 5 minutes of work. All of the fluids are fresh and the battery is ready to do its job. I'll ride it without the side panels for the summer because I'm not sure of the direction I want to take with them yet. Also, until I have an opportunity to shake it down, no paint.

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IMG_3046.JPG

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

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