[DY's] SV650 Winter Project

[DY]

open for discussion. If future updates are not directly under the previous. A link "next update" will be at the bottom of each post.

this is to document my progress with my new to me SV650.

After spending 2 years on the CBR250, I finally decided to upgrade to a bigger bike. That thing was getting cramped!

It was either going to be the SV650 or a 600. It was a hard decision but the SV was the "logical" upgrade. (The irrational side of me wanted me to get a 600. but three grand for insurance, no thanks )

After getting a chance to ride it, I don't regret this decision at all. It has torque out the wazoo. Half the time I didn't know what gear I was in. just give it gas and it goes!

The bike is an 02 SV650S trackbike. the engine is mildly tweaked. chassis wise, it has a rear Ohlins and RT emulators up front. It has a clean title so I will be converting it back to a streetbike for next year. It will pull double duty as both a street and track machine.

To make going to the track easier, i've decided to build a naked SV and just keep the current fairings for track use. The easier it is to convert, the better.

The bike started as this:


The previous owner also gave me 90% of the street parts.

some of big things i plan to do:
- complete tear down, clean, and inspect every part.
- powdercoat the frame, swingarm, bits and pieces.
- GSXR front end.
- GSXR 5.5" rear wheel conversion.
- braced swingarm.
- Koso digital gauges
- rizoma signals (still need funding for this one)

Alot of the stuff is cosmetic and for bling. Yes, I know. I don't care it doesn't make me a faster rider or has no performance value.

That's it for now. there will be alot of small mods along the way. hopefully I can keep the camera handy with everything I do.

day one of owning the bike (late October): already stripped down. then winterized.


More updates coming soon.

[DY]

More updates from before:

October:
- Picked up an 04 GSXR 750 front end from Glen @ FS-motorcycle. Also picked up a headlight, frame sliders, bar end mirrors.


These forks are in great shape. looks real good after I cleaned them up a bit. I still need 50mm clip-ons and a front wheel.

Earlier November:
- couldn't wait for next season to try the bike out. Decided to take it out to Cayuga. It didn't go exactly as planned and I had small get off. Nothing major on the bike whatsoever. I got a bit banged up however. Decided to call it a day and brought the bike back home. That was the season for me.

- To drop the engine and remove the swingarm, I had to get those castle nuts off. I bought some sockets from PA and grounded them down.



The smaller socket fits the two smaller nuts (upper and lower engine mount)


The bigger one fit the two bigger ones (engine mount, swingarm)


Here are the dimension for the sockets. Any 12 point socket with the same outer diameter will work.




This is how it looks as of now:




I still have to prepare the frame for powdercoating. the subframe is already plugged up, ready to go. Can't figure out a good way to cover the mounting holes yet.

The engine covers are going for paint as well.

November 14, 2009:
- to do the GSXR front end on 1st gen SV, I needed a special bearing kit. I spoke to Zoran from Twin Works Factory and a set is on the way. Top guy to deal with, it took only 2 hours when I first emailed him to me sending money via paypal.

November 19, 2009:
- After talking to Aaron from Weirtech (www.weirtech.ca). I dropped off my swingarm at his shop. He said it will probably be ready in about 2 weeks. Here is one of the custom one's Zoran made.


Here are some concepts I did at work. Yes, I do something else other than surfing GTAM all day. I liked the looks of the round tubing the best and decided to go with that. Aaron said he preferred to work with round tubing as well . most would do the square tubing because its the easiest to work with.


*WARNING* this purely a performance mod. I ride it so fast that I can feel it flexing under me. i need this extra rigidity to break the sound barrier. Don't Hate!

November 20, 2009:
- Browsing E-Bay one day. I saw a 2003 GSXR 600 rim on bid for $20. for the heck of it, i placed a bid last minute. Ended up winning it for $70 with the rotors included. It arrived today.





I thought, for this price, something was gonna be wrong with it for sure. But after some inspection, it looks alright. rim is straight. so are the rotors. lots of life left in them as well!

Thats it for now. The waiting game continues.

Next up would be making the spacers for brake calipers. I believe I need either 5 or 10mm spacers. Will have to check on svrider.com

[DY]

Did some more reading on Svrider.com.

Since the rim is off a 2003 gsxr 600, I have to make 10mm spacers for them.

97-03 gsxr 600-320mm
96-03 gsxr750-320mm
all tl/busa-320mm
01-02 gsxr1000-320mm
03-04 gsxr1000-300mm
05 gsxr1000-310mm
sv1000-310mm
04-05 gsxr600/750-300mm
06's-310mm
they all have same bolt patern except 05 gsxr 1000 and 06's all gsxr's.
97-01 gsxr600,96-00 gsxr750,busa and tl are srad generation and wheels and rotors interchange.
rest of them are newer gen and all wheels work as long you have wheel and rotor combination that works for your forks.bigger diameter rotors will work with spacers and longer caliper bolts.smaller will not.
hope that is clear.

December 1, 2009:

- Not much progress. Still waiting for parts. I've been very busy (and lazy). I'm also REALLY procrastinating the prep work for powdercoating.

- Spoke to Aaron from Weirtech. He said the swingarm should be ready by the end of this week. once the swingarm is here, everything is going out for media blasting then paint.

- The tapered roller bearing I ordered from www.TWFracing.com finally got here after three weeks. Zoran is a top guy to deal with. Always answered emails promptly and even sent instructions with the bearing!


- Another thing I'm installing would be a damper. I have a Sprint Damper that I kept when I sold my R6. Not technically needed for the SV unless one really screws with the steering geometry.... But why the heck not, I got it for free. The GSXR forks already have provisions for a steering damper so adapting this should be easy.

Its been said a damper is one of those things that "you don't need until you wished you had one".


- Also snagged a GSXR fender and these 50mm headlight mounts. Everything including shipping was $77. definitely a steal.



That would be it for now.

[DY]

December 4th, 2009:

- Picked up my swingarm from Weirtech. Great work. looks amazing.



- also bought a roll of special powdercoating tape. I will be doing the masking myself for a piece of mind.

December 5th, 2009:

- All the parts are ready to go for sandblasting next Monday. Everything is masked off.

- Got the ignition out of both triple trees. I just drilled the safety screws out. Not worth buying the bit just to do this.


- Both valve covers are off and will go to sandblasting with the other parts.



By next Friday, I should hopefully have everything painted and ready to be put back together. Hoping to find some swingarm, linkage bearings for cheap as well.

There should be alot of updates next week. I only have until end of this year to finish most of the bike. School is starting up again in January and I won't have much time to work on it until April.

[DY]

December 7th, 2009:
- Took the frame, subframe, swingarm, valve covers to Soda Pro (www.sodapro.com). Should get them back Wednesday, the 9th.

December 8th, 2009:
- Made the brake caliper spacers myself. As mentioned above, I needed 10mm spacers to make up for the bigger disks.

I don't want to do this again. it took way too long on my mini-lathe. about 4hrs to make four spacers from 1" stock.


Here is the lathe:
just for size comparison. the spacer is about 1" in diameter.




- Got my GSXR fender in the mail today. Looks great. It even has the OEM white sparkle paint on it. no blemish at all. not bad for $30.

[DY]

December 9th, 2009:
- Picked up my parts from Soda Pro. Very very pricey. way too steep for me but there was no other way to do it. everything came out absolutely perfect though.






Here you can see all the holes plugged up as well. It is always better to take the time to plug it rather than cross threading every hole after. PC is a huge pain to take off since its so thick.


- The same night I spent 4hrs masking everything off for paint. It was a huge PITA! the special tape is not very flexible and is more like a hard plastic sheet than tape. Before taping, I also wiped all the surfaces with alcohol to get all any dirt off. If the tape was too big, they had to be trimmed down to size with a knife as well.





December 10th, 2009:
- Dropped by Jet Cote after work today. Hit some traffic along the way and they closed right when I pulled in. I literally passed the workers leaving the parking lot as I drove in. Definite piss off for sure.

December 11th, 2009:
- Woohoo! Everything is off to paint. I left early for work this morning and dropped by Byers Bush before work. I wasn't satisfied with their colour choices and it would be stupid expensive for them to order special powder for me just to get the job done. So I only left my frame and subframe with them to get it coated in semi-gloss black.

- Later that morning, I called Fireball Coatings in Erin. They had the colour in stock and could get it done it 2-4 days. I decided to drive up afterwork and get it to Mark. that was a long *** drive up!

- I have to buy new swingarm linkage bearings next week and get this baby back together.