SuzukiSavage.com - My $40 Savage

magnum440d100 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 26	Re: My $40 Savage Reply #15 - 06/20/18 at 14:56:54 After one round in the cleaner. I couldn't get the screw out due to a LOT of crud. After the first go around, I was able to remove that screw for a better clean...
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magnum440d100 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 26	Re: My $40 Savage Reply #16 - 06/20/18 at 15:00:42 The project was almost over before it began! Someone attempted to remove this screw before and just about stripped the head! Luckily a pair of vice grips grabbed the head JUST right and I was able to break it free. The alternative would NOT have been pretty!
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magnum440d100 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 26	Re: My $40 Savage Reply #17 - 06/20/18 at 15:03:46 I am absolutely blessed that the diaphram is in great condition!! I may not need a kit right away. Maybe a thorough cleaning will do wonders! (I can hope, right?? HAHA)
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: My $40 Savage Reply #18 - 06/20/18 at 19:24:56 Be aware that rebuild kits bought on line often come with jets of the wrong size,(smaller) the stock jets for the Savage are 52,5 pilot 147 main.
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Re: My $40 Savage
Reply #19 - 06/20/18 at 19:53:46

[quote author=62595443525E454358505D42310 link=1529202769/0#10 date=1529494008]magnum440d100 wrote on 06/19/18 at 19:33:36:

batman wrote on 06/17/18 at 17:28:00:

So, NO flat washer required? 10-4!

The rear idle gear that is closest to the starter motor does not get any washers.

The other idler gear that has the splined shaft and the torgue limiter requires a flat washer on both sides (inner/outer).

I've now read 2 versions of the Clymer (print and digital) and there is no mention of a washer. If it is supposed to be there, I WANT to put it back on. Do you have any part numbers or links to said washer(s)? Hopefully this doesn't come across as rude, as it is not meant to be. I am genuinely curious!

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Re: My $40 Savage
Reply #20 - 06/20/18 at 20:01:40

batman wrote on 06/20/18 at 19:24:56:

Be aware that rebuild kits bought on line often come with jets of the wrong size,(smaller) the stock jets for the Savage are 52,5 pilot 147 main.

Good info, Thanks! Is there a preferred kit or manufacturer? I was just going to go to the local cycle shop and purchase there, but if there's a tried and true brand that can be had more economically, that would be ideal. I'm still trying to stick to a $500 budget! Just a personal goal, not wholly necessary though haha

Speaking of budget, here's where I'm at:

Bike: $40
Battery: $100
Starter Gear: $50
Clymer: $30

So $180 into my $500 budget (not counting purchase price) leaves me $320........

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: My $40 Savage Reply #21 - 06/20/18 at 20:49:38 washers (2) one on each side of the torque limiting gear (the gear with three sets of teeth) Suzuki part number 09181-10167 (about $1.30 each)
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magnum440d100 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 26	Re: My $40 Savage Reply #22 - 06/20/18 at 21:02:23 batman wrote on 06/20/18 at 20:49:38: washers (2) one on each side of the torque limiting gear (the gear with three sets of teeth) Suzuki part number 09181-10167 (about $1.30 each) That is amazing, Thank You!
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Re: My $40 Savage
Reply #23 - 06/21/18 at 00:39:01

Last question of the night, I promise haha.

so, I've got the carb torn down fairly far and I've been running it in the ultrasonic. I ran it a couple times to facilitate easier disassembly, due to how much crud there was. So, I'm down to everything off besides the floats and needle. I cannot seem to get the float pin off/out. In the Clymer, it says to "Remove pin" to take off the floats. but it doesn't show HOW to remove the pin! I've tried a drift and tapping from the small side towards the big side, I've tried getting something behind the big end and prying slightly, I've tried both at the same time even! It will NOT budge!!!

I'm ASSUMING that it's just pressed in there. And I'm ASSUMING that it's stuck in there due to the amount of crud that was in the bowl. Maybe it rusted (or oxidized, if you will) and is seized to the aluminum???

What am I missing?!?!?!?!

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Re: My $40 Savage
Reply #24 - 06/21/18 at 03:13:21

[quote author=2824222B302871717521747575450 link=1529202769/15#19 date=1529549626]Dave wrote on 06/20/18 at 04:26:48:

magnum440d100 wrote on 06/19/18 at 19:33:36:

batman wrote on 06/17/18 at 17:28:00:

So, NO flat washer required? 10-4!

The rear idle gear that is closest to the starter motor does not get any washers.

The other idler gear that has the splined shaft and the torgue limiter requires a flat washer on both sides (inner/outer).

I've now read 2 versions of the Clymer (print and digital) and there is no mention of a washer. If it is supposed to be there, I WANT to put it back on. Do you have any part numbers or links to said washer(s)? Hopefully this doesn't come across as rude, as it is not meant to be. I am genuinely curious!

The Clymers manual was written and photographed using an early version of the bike that did not have a torque limiter gear.

Using an onlne parts diagram is very often a good way to see where things go......the part number....and what the parts cost.

https://www.bikebandit.com/oem-parts/2014-suzuki-boulevard-s40-ls650/o/m15649...

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magnum440d100 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 26	Re: My $40 Savage Reply #25 - 06/21/18 at 14:07:09 I think the carb killed my ultrasonic cleaner! Hahaha After running it through a couple times, here's what the cleaning solution looked like... It's supposed to be yellow/yellow green....
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Re: My $40 Savage
Reply #26 - 06/21/18 at 14:11:09

Not sure what all that crap is, but its what was left on the bottom of the tank of the ultrasonic cleaner..... This was fresh cleaning solution put in just before the carb...

Whatever it is, my ultrasonic stopped working. I put fresh solution in, and now heat doesn't work anymore, and the cleaner runs only for a few seconds before it flashes E01 and shuts off......

I've unplugged it, and I'm going to let it sit for a bit and plug it back in... Hopefully its something simple....

But the carb came out SPARKLING!!!

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Re: My $40 Savage
Reply #27 - 06/21/18 at 14:27:28

Your correct in thinking that the pin is only pressed in and that it only comes out in one direction , be careful of how much force you use the carb body is just pot metal. the best penetrating oil ever tested was a 50/50 mix of acetone- (fingernail polish remover), and ATF . you cold apply this to the pin area a few times,( the acetone evaporates quickly) and then try pressure. good luck!

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Re: My $40 Savage
Reply #28 - 06/21/18 at 18:44:26

AAAAANNNNNNNND then this happened. Or maybe it already was bad....

Got the bike to pop once, and then nothing. Just a super fast crank... Been there before, and knew what it was....

SO, on top of the list of things to do, now is the timing chain...

My only concern at this point is whether this engine is an interference or not...... ugh....

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Re: My $40 Savage
Reply #29 - 06/21/18 at 18:59:21

Things are close enough that it is an interference fit - however I suspect that with only 1 bang.....nothing was spinning fast enough to create a condition where the valves were open when the piston came up to the top.

The only way I can think to check - is to either take the head off and look, or to put it back together and do a compression test to see if the valves still seal.

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