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  1. #21 Re: SAGA 250 mod thread 
    C-Moto Senior kens's Avatar
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    Oct 2008
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    BC CANADA
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    117
    I finaly got around to pulling the swing arm off to check why the swing arm has excessive play.What I found was not bad plastic bushings but that the bolt to steel bushing clearance is over .0015 thou and should be like .0004 ish.

    So off to the machine shop I went to have some made that are right.I think the bushing ( plastic and steel ) are correct...and that the culprit is the fact bolts are always undersize from the true size.

    I will post pictures when I get the new ones from the machine shop.
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  2. #22 Re: SAGA 250 mod thread 
    C-Moto Senior kens's Avatar
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    Oct 2008
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    BC CANADA
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    I am now having all the bushings in the suspension custom made for all the suspension.I was so impressed with the swingarm bushings that the rest been so "shitty" loose was not right.

    This should tighten up the bike very nicely.

    Pics to come
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  3. #23 Re: SAGA 250 mod thread 
    C-Moto Not-so-Noob
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    Feb 2009
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    38
    hi ken , i know its off topic but just had to brag that i went for a ride today in to the blaeberry [iob] . still cold and slippery but quite nice to be able ride this early around here
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  4. #24 Re: SAGA 250 mod thread 
    C-Moto Senior kens's Avatar
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    Nice!!!! I bet it is still cold up in the valley!!!
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  5. #25 Re: SAGA 250 mod thread 
    C-Moto Senior kens's Avatar
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    Oct 2008
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    Got the swing arm back in last weekend with the new machined "link pins" to replace the bolt that contributed to the "clunky" rear suspension.The bolt on the three way link ( from the shock/swing arm/engine) that goes to the swing arm had a incredible amount of play because the bolt used in the assembly did not have enough shoulder to carry over and thru into the other side of the bracket. At that point it was on the treads that are thiner than the rest of the bolt and had a lot of movement.

    On the swing arm I ended up having new steel bushings made also to fit the factory axle bolt.This got rid of all the excessive swing arm play
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  6. #26 Re: SAGA 250 mod thread 
    C-Moto Noob
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    Sep 2009
    Location
    Prince George, B.C.
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    3
    Mobile Photo 2010&#4.jpgI just finished installing my new coil and cdi box that I just recieved from toys4boys inMobile Photo 2010&#4.jpg Calgary. Was a little bit of work but I was able to put all the new parts in the exsiting places so didn't have to modify anytMobile Photo 2010&#4.jpghing to much. The real pain in the ass was trying to reinstall the gas tank as it didn't want to sit back in place properly. AMobile Photo 2010&#4.jpgfter a nasty cut on the finger and some blood spilt I was able to get it to fit again. Here are some pics I took along the way.Mobile Photo 2010&#4.jpg
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  7. #27 Re: SAGA 250 mod thread 
    C-Moto Noob
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    Sep 2010
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    Drumheller, Alberta
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    1
    Hi guys, it's awesome to find some info on these bikes. I bought mine in the spring and have almost 500 km on it now, it feels like it's breaking in a bit now. I've only done a couple minor mods so far, the first was to raise the main needle for the crappy starting and idling problems that seem to be common. I die ground out the mount holes for the headlight to get it out of oncoming traffics eyes. The little acerbis headlight does a pretty good job on there I think. Has anyone done any airbox or exhaust mods?
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  8. #28 Re: SAGA 250 mod thread 
    C-Moto Not-so-Noob
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    Oct 2010
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    Victoria, BC, Canada
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    11
    Hi,
    Just piked up a Saga myself, and am looking to do some work on it. For where I ride the headlight is not going to cut it, does anyone know what type of base the bulb is?
    Is there a higher wattage bulb avalible?
    I'm also looking to change out the airbox for a pod filter and put a new exhaust in there or gut the stock one. I'm assuming there is no point going bigger than the 30mm carb without getting some more flow out of the head?

    As soon as I brought it home I did a new sprocket, plug, and raised the needle a notch but I would like more power if possible.
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  9. #29 Re: SAGA 250 mod thread 
    C-Moto Not-so-Noob
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    Oct 2010
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    Victoria, BC, Canada
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    Ordered a bunch of jets, a UNI filter and a performance CDI today and am looking in an exhaust for it. I'll make changes one at a time too see what effect they have.
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  10. #30 Re: SAGA 250 mod thread 
    C-Moto Not-so-Noob
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    Oct 2010
    Location
    Victoria, BC, Canada
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    11
    Mmm installed the CDI (same one as toys4boys currently sells) and it's missing at idle and seems a little harder to start, will have to look at it further tommorow.
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