Author Topic: Suzuki XR440 SM40L Restoration  (Read 11449 times)

Online Rupp luver

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Re: Suzuki XR440 SM40L Restoration
« Reply #40 on: April 18, 2013, 06:17:11 PM »
  L!k3   NICE work zuk!
"I build FUN sleds,NOT show sleds"!!
Wahpeton,ND home of:
1970 Rupp Rat sled[JLO 440 F/A]
1970 Rupp Racer[JLO R295]
1970 Rupp Magnum 440WT[Sachs 440]
1970 Rupp Sprint 40[399 Hirth]
1970 Rupp Sprint 29[JLO L295]project
1970 Rupp Sprint 28[Sachs SA 280]
1971 Rupp Sprint 44[396 Yamaha,Scorpion track]

Offline zuknomad

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Re: Suzuki XR440 SM40L Restoration
« Reply #41 on: April 20, 2013, 06:03:11 AM »
Thanks, Rupp luver. Looks like I'll be playing with the idler configuration a little. I checked the fit of the axle assembly into the 'good' track and found that the idlers don't contact the track, because the Raider drivers are slightly larger in diameter than the old Suzuki drivers were. Looks like I'll need some larger diameter idler wheels.

Here are two choices I'm playing with, both are 5 1/4" O.D. Suzuki bogie sled spares. The NOS aftermarket ABS plastic ones I had were easy to work, so I tried those first. The hub width space between the washers and retaining circlips is 6mm narrower on the sliderail axle than on a bogie axle, so I ground the excess off the plastic hubs and fit them...



When this set-up was test fit, the idler now contacts the track completely, but only the teeth of the driver contact the track windows. No part of the driver hub makes contact with the track..

Now I'm looking for some help from you guys. What's the right amount of contact for the idlers and exvolute drivers to share on a cleated track?
'anyone can drive a new sled, it takes some dedication to run crap'

Online Rupp luver

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Re: Suzuki XR440 SM40L Restoration
« Reply #42 on: April 20, 2013, 12:42:19 PM »
I think your idler is too high.The idlers might wear down with time & be ok. The track drive cleat should at least lay in the flat section between the teeth or be close.Lay a straight edge across your sprocket[the area at base of teeth] & idler. P3n
"I build FUN sleds,NOT show sleds"!!
Wahpeton,ND home of:
1970 Rupp Rat sled[JLO 440 F/A]
1970 Rupp Racer[JLO R295]
1970 Rupp Magnum 440WT[Sachs 440]
1970 Rupp Sprint 40[399 Hirth]
1970 Rupp Sprint 29[JLO L295]project
1970 Rupp Sprint 28[Sachs SA 280]
1971 Rupp Sprint 44[396 Yamaha,Scorpion track]

Offline zuknomad

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Re: Suzuki XR440 SM40L Restoration
« Reply #43 on: April 20, 2013, 07:52:53 PM »
I think I understand what needs to be done now, Dan, and you're right, the bogie idlers are too tall. I'm gonna have the machinist take 1/4" off the diameter of them for me. It's the thickness of the track, and then the flats between the driver teeth will make light contact on the track as the teeth grip the cleats. It should also make the track contact between the idlers and drivers about even. I get it now.
'anyone can drive a new sled, it takes some dedication to run crap'

Online Rupp luver

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Re: Suzuki XR440 SM40L Restoration
« Reply #44 on: April 21, 2013, 04:30:01 PM »
Be careful on how much you take off,cause you can't put it back on! I would bring the whole front drive shaft with everything on it;that way you can try,fit/measure. Just a thought. P3n
"I build FUN sleds,NOT show sleds"!!
Wahpeton,ND home of:
1970 Rupp Rat sled[JLO 440 F/A]
1970 Rupp Racer[JLO R295]
1970 Rupp Magnum 440WT[Sachs 440]
1970 Rupp Sprint 40[399 Hirth]
1970 Rupp Sprint 29[JLO L295]project
1970 Rupp Sprint 28[Sachs SA 280]
1971 Rupp Sprint 44[396 Yamaha,Scorpion track]

Offline zuknomad

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Re: Suzuki XR440 SM40L Restoration
« Reply #45 on: April 21, 2013, 07:19:17 PM »
And it's a good thought. He's got the axle, drivers and idlers, we met in town this afternoon and I gave him everything. I originally thought about giving him the original (junk) track too, but that's not the one I'll be using. The better (replacement Quimpex) track is still on the other XR.

If it's anything like his workmanship on the mount plates, it'll be better than anything I could have done, and it'll be right the first time.
'anyone can drive a new sled, it takes some dedication to run crap'

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Re: Suzuki XR440 SM40L Restoration
« Reply #46 on: April 21, 2013, 09:57:45 PM »
It shouldn't really matter what track you use,they should fit the same,a track is a track,new or used. P3n
"I build FUN sleds,NOT show sleds"!!
Wahpeton,ND home of:
1970 Rupp Rat sled[JLO 440 F/A]
1970 Rupp Racer[JLO R295]
1970 Rupp Magnum 440WT[Sachs 440]
1970 Rupp Sprint 40[399 Hirth]
1970 Rupp Sprint 29[JLO L295]project
1970 Rupp Sprint 28[Sachs SA 280]
1971 Rupp Sprint 44[396 Yamaha,Scorpion track]

Offline zuknomad

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Re: Suzuki XR440 SM40L Restoration
« Reply #47 on: April 22, 2013, 06:17:58 AM »
I never have measured the belt thicknesses to see if they're the same, Rupp luver. That would be the only thing that could make any difference, as far as how far the teeth would stick through the windows upon rotation. I wish the Quimpex was new; it's just a lot newer than the Suzuki track and in much better shape.

Trying to keep this easy for this guy, too. His prices for the work are cheap, and his health prohibits moving stuff like that track right now.
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Offline zuknomad

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Re: Suzuki XR440 SM40L Restoration
« Reply #48 on: April 28, 2013, 06:39:06 PM »
Still waiting on those idlers, had to give them back to my friend to take another 1/8" off the diameter, as they were still just a touch tall.  pc..n

So I tackled the cleaning and rust removal on the largest piece of the exhaust system, the expansion pipe, or what Suzuki called the 'first' muffler. At 2800 miles, probably the grungiest one I've had to do yet, my Nomads have had about 1/3 of those miles. Still was surprised with how solid it really was. Some final hand work for rust in the crevices was done, followed by a very thorough cleaning using air, thinner on a clean cloth and a lastly, a tack rag. Between yesterday and today, all four pieces got base coats of Rustoleum Rust-Stop BBQ grill paint in the 65F+ degree temps outside, which dried quickly. The flat look of the Rustoleum isn't close to the original semigloss Suzuki applied at the factory, so the three parts that will be visible when the hood is open got topcoats of Krylon 1200 degree satin black. The '2nd muffler' will be forever buried under a cover in the bellypan void, so it was left in the Rust-Stop flat...

'anyone can drive a new sled, it takes some dedication to run crap'

Offline zuknomad

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Re: Suzuki XR440 SM40L Restoration
« Reply #49 on: May 01, 2013, 08:22:22 PM »
Got my idlers back today, and like I said the machinist is a very fair guy. Didn't charge me anything for taking the final 1/8" off of them. Here's a test fit on the 'good' track, which is still attached to the other XR...

'anyone can drive a new sled, it takes some dedication to run crap'