Suzuki 650BTS - Another LS650 S40 Savage build? Why?

Discussion in 'Some Assembly Required' started by pekingduck, Jul 23, 2017.

  1. Kai Ju

    Kai Ju Long timer

    Joined:
    Jul 29, 2009
    Oddometer:
    2,925
    Location:
    Long Beach, California
    Looking really good on the details, can't wait to see it in the flesh, so to speak. Need to see an overall shot, I'm having a hard time printing out all the individual shots and putting them together...
    I'm surprised though you didn't just weld the mounting brackets to the chain guard, vs. the bolts/nuts.
  2. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    I'll post pics in the next couple days. I used steel brackets, and the top of the chain guard was aluminum, because I thought I would like to keep the anodized finish, but there was too much brightwork.
  3. Kai Ju

    Kai Ju Long timer

    Joined:
    Jul 29, 2009
    Oddometer:
    2,925
    Location:
    Long Beach, California
    You don't have one of those fancy machines that welds aluminum to steel ? Bummer.
  4. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    I rolled the bike off the lift today for the first time, and put 2 gallons in the tank, and it primed the fuel system readily. It started easily and idled fine, but I could tell it needed re-jetting.

    I noticed also that the red oil pressure light was staying on! I had wired the Triumph dash lights to the Suzuki harness, tested it (but didn't start it), so everything seemed fine. I have no idea what it was hooked to, since the Suzuki does NOT have an oil pressure light (or switch) since it has a roller bearing crank, which runs low oil pressure. So I rewired the low fuel light to it instead.

    IMG_6669-2.jpg
    xaman, richardl and Jay_In_Milpitas like this.
  5. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    Got the bike running, started and idled fine, then played with the mixture screw. And then it wouldn't start at all. Cranks fine, but no spark. Tested pulse generator output and resistance, was fine. Found the ground cable loose, thought it may have nuked the black box! Took the tank off (a big ordeal) to check plug and coil and found that in shoving the throttle cable under the tank, one of the coil wires was dislodged. Put it on, reassembled it, and test rode it. Needs a little larger pilot jet, maybe raise the needle a bit. Checking the plug will be very hard to get at - pull the tank each time.
    Jay_In_Milpitas likes this.
  6. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,786
    Location:
    Heart of America
    Totally worth it once running well.
  7. Jay_In_Milpitas

    Jay_In_Milpitas Zero to sixty in February

    Joined:
    Feb 25, 2016
    Oddometer:
    311
    Location:
    Milpitas, CA
    Perhaps a temporary/test tank while dialing it in?
  8. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    The chrome cover on top of the engine blocks the spark plug. I'll have to pull the tank off and remove the cover. I'm waiting for a larger pilot jet I ordered, then will attack it next week.

    IMG_6960.JPG

    I had delayed all last week because I found some NSU Max/ Supermax derelicts. I found 4 so far, and have leads on 3 more. Why? I don't know. I had one 5 years ago, never got it running, and would like to make one good one out of the lot.

    Yikes! Bikes! There may be enough for one good bike.
  9. Wildebeest90210

    Wildebeest90210 Long timer

    Joined:
    May 24, 2013
    Oddometer:
    1,654
    Put them in a container, ship them to the UK and count up your $$$$$
    Nemosengineer and villageidiot like this.
  10. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    In the mean time, here is the bike in its present condition. Footpeg/seat/controls/handlebars perfect fit. Brakes and controls work fine. Only have to sort out the jetting a bit and have the exhaust coated - silver? or black?

    Thanks to THE TUCKERS for the name suggestion. Mestizo would have been good too. These custom tank and sidecover stickers were about $6 pair from eBay.

    IMG_6957.JPG IMG_6959.JPG
    xaman, Scoozi, TonyKZ1 and 3 others like this.
  11. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    The scars on left side of the tank, which was the reason it only cost $115, were hidden by the Motone brand knee pads, same as the Triumph but no name. I mounted them a bit higher to cover almost all of the scratches.
    tank3.5.jpg

    I found an aftermarket Harley gas cap that was cheap and trick. Push down on the center and rotate slightly, and a knurled knob pops up to grip and spin off. Also, mounted the helmet lock in the only place possible.

    Untitled.jpg

    In the mean time, here is the bike in its present condition. Footpeg/seat/controls/handlebars perfect fit. Brakes and controls work fine. Only have to sort out the jetting a bit and have the exhaust coated - silver? or black? Vibration is a lot less than a Honda XL/XR 600/650, maybe less than a GB500.

    View attachment 1040303 View attachment 1040304
    TonyKZ1 likes this.
  12. everready

    everready Stuck in Ohio....Ugh!!!

    Joined:
    Jul 1, 2013
    Oddometer:
    2,143
    Location:
    Macedonia, Ohio
    Bitchin'!
  13. Jay_In_Milpitas

    Jay_In_Milpitas Zero to sixty in February

    Joined:
    Feb 25, 2016
    Oddometer:
    311
    Location:
    Milpitas, CA
    Regarding the NSU's, that's just a whole lot of sexy there. The Super MAX is another bike I would like to see produced with modern metallurgy and production techniques. The tool boxes and oil tank alone make happy feelings in my naughty parts.

    Your Mongrel is a version I feel strongly that Suzuki should produce. I owned a Savage and rode it between Spokane & San Jose at times. The engine is just fine, but the cruiser ergonomics and little gas tank were a nuisance. Yours seems to be Just Right.
    TonyKZ1, BPadge and Kai Ju like this.
  14. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    Got the exhaust back from the ceramic coaters and installed it. Yesterday I had rejetted it yesterday, one size larger pilot, shimmed the needle up - we'll see how it runs. Starts and idles easily, takes throttle happily, sounds healthy but not too loud.

    The footpeg bar allows enough room for a low pipe if desired. The pipe is reasonably quiet, but the bolt-in restrictor at the back can be replaced with one with a smaller opening. I wanted to put a "snuff-or-not" in there, but it would have been too loud even closed.

    IMG_7070.JPG

    IMG_7074.JPG

    IMG_7072.JPG

    IMG_7088-1.jpg
    TonyKZ1 and invisa-bill like this.
  15. pekingduck

    pekingduck Been here awhile

    Joined:
    Jul 21, 2017
    Oddometer:
    195
    The project is finished. The goal was to make a bike like the factory would have made, with all functions. It took 5-1/2 months and a grand total of $3351 including the price of the bike and registration, minus $377 for parts sold. Net cost is $2974 (plus I still have that RYCA Scrambler seat to sell). So it went from a "custom" to a "standard", and I'm pretty happy with the results. It weighs 341 pounds filled up, has lots of legroom, handles very nimbly, and has a decent amount of grunt.

    IMG_6289.JPG

    IMG_7088.JPG

    IMG_7083.JPG

    IMG_7073-1.jpg
    TonyKZ1, xaman, invisa-bill and 4 others like this.
  16. everready

    everready Stuck in Ohio....Ugh!!!

    Joined:
    Jul 1, 2013
    Oddometer:
    2,143
    Location:
    Macedonia, Ohio
    Very nice. It kind of has the same lines as a Royal Enfield to me.

    Edit: A robust skid plate would look great, IMHO.
    pekingduck likes this.
  17. r60man

    r60man Long timer

    Joined:
    Mar 14, 2013
    Oddometer:
    1,290
    Location:
    Robesonia PA
    I like that a lot. Great work and not a heck of a lot of scratch involved.
    pekingduck likes this.
  18. Tanshanomi

    Tanshanomi Your Favorite Uncle

    Joined:
    Jul 22, 2009
    Oddometer:
    1,786
    Location:
    Heart of America
    Nice result! Well done.
  19. Jay_In_Milpitas

    Jay_In_Milpitas Zero to sixty in February

    Joined:
    Feb 25, 2016
    Oddometer:
    311
    Location:
    Milpitas, CA
    Splendid job. How does it ride? Will there (please) be videos?
  20. everready

    everready Stuck in Ohio....Ugh!!!

    Joined:
    Jul 1, 2013
    Oddometer:
    2,143
    Location:
    Macedonia, Ohio
    You know, this looks like the kind of bike Ed from the Edventure thread would like.