1st Gen SV650 Build | GTAMotorcycle.com

1st Gen SV650 Build

Brian84

Well-known member
I've been riding motorcycles for the last 5 years or so now, but only recently decided to get into customizing my bike, and learning how to do most of the work myself. I've been posting this on svrider.com at: http://www.svrider.com/forum/showthread.php?t=248633, but I figured it would be good to post on GTAmotorcycle as well, since I live in Toronto.

I bought the SV650S in the summer of 2012, with the intention of turning it into a naked bike. I had ridden a ZX6R before the SV, but wanted something a bit less aggressive, and a bit more city friendly. Not to mention a lot more fun to tinker with! This is what it looked like the day I bought it:
2012-04-06-13.42.04-1024x768.jpg


Last year I converted it to a naked bike, but I still had the crappy suspension, and everything else was pretty much stock. I was inspired by some posts on this forum, and realized that there are lots of people doing amazing things to their bikes! Changing my bike to naked was basically the first time I'd tinkered with a motorcycle at all, and since I enjoyed it so much, I thought this winter I would completely customize my SV.

This is what it looked like last spring:
2013-11-19-15.00.57-768x1024.jpg


The plan is to do the following:

-Strip the bike down

-Powdercoat the frame and all other metal parts black

-Make my own custom subframe, along with either a ducati monster seat or a custom made one

-2008 GSX-R600 fork swap, with custom made triple tree for handlebars and to keep the stock steering lock and ignition placement

-2003 636 rear shock

-Rebuild everything!


I already have a headlight from Aztec8, but I'll have to make my own headlight brackets as well to fit the GSX-R forks. I'll also have to modify small things such as the steering stop to fit the new forks. Oh, and I want this to be done by the spring at the beginning of the riding season, so say April!

Over the last couple of months I started acquiring parts. I picked up a set of 2008 GSX-R600 front forks:
2014-01-20-22.19.13-768x1024.jpg


I also picked up a 2007 front wheel with rotors, 2009 brake calipers, and a 2009 radial master cylinder:
2014-01-20-22.19.46-1024x768.jpg

I bought the wheel off ebay, but they didn't pad it very well for shipping, so I hope it didn't get damaged in the process. The forks however are in immaculate shape, and were a great deal!

So far I've stripped the bike down to its parts. Here's the process I went through so far:

Starting the work, gas tank and carbs out:
2014-02-10-20.50.54-1024x768.jpg


I had to grind down a couple of tools to remove the castle nuts holding the engine, so I bought a small angle grinder and made some tools out of some cheap sockets:

Note the awkward position (all my bench space was used up):
GrindingTool-e1393366884966.jpg


Castle nut socket:
2014-02-19-17.10.56-1024x768.jpg


Finally removed the engine. That thing is heavy! Although I can't say I was too surprised:
2014-02-19-19.09.46-1024x768.jpg


It looks like the previous owner did some electrical work to get these integrated tail lights to work. I hate cutting wires, but some of these have been hardwired into the stock harness:
2014-03-02-16.37.04-1024x768.jpg


Lots of wiring!
2014-03-02-17.26.39-1024x768.jpg


This was maybe a stupid decision, but my steering stem head nut got cross-threaded and was completely stuck. So I took my cut-off wheel to it and went nuts. Kind of cut through the steering stem in the process:
2014-03-02-19.07.26-1024x768.jpg


Finally the end result: my bike is gone! Lots of parts in its place.
2014-03-02-19.51.29-1024x768.jpg


Just have to get the frame and other parts powdercoated, and start making a subframe.

Are there any welders out there who would be interested in helping me fabricate a subframe for a custom seat? :toothy5: I've taken a stick welding course, but am not really able to set up a welder in my parents garage at the moment, and I don't have the skill yet to build my own subframe.

Stay tuned for more updates here, or on my blog at http://www.ofmindsandmotorcycles.com
You can also see more pictures as I update them at https://www.facebook.com/mindsandmotorcycles
 
Keep it coming and let us know how it all pans out in the end...!
 
Going to be a rewarding project!
 
So for the past couple of weeks I've been doing more waiting and sourcing parts than actual building. With the weather getting better soon, I'm anxious to get this thing back together again!

I took a trip to Niagara Falls to pick up a gsxr fender, '03 636 rear shock, and...
2014-03-10-15.37.23-1024x768.jpg


That's right! A Suzuki Katana seat of course! What, I'm crazy?

Perhaps... I was inspired by this:
2006-suzuki-katana.jpg


I'm not sure if it will work for my bike yet, but for $45 off of ebay, I didn't think I could go wrong with giving it a try. If it doesn't work I'll either go back to the ducati monster seat idea, or fab one up myself. I might even cut away at some of the plastic to try to shape it properly against the tank so it fits snug.

The frame, swingarm, and wheels are ready to go for powdercoating, flat black. I'll be dropping them off with JonnyP636 tomorrow, or at least sometime this week.

Stay tuned...
 
That's a lot of work. I bet this turns out awesome. Good for you for making something your own :cool:

Thanks! This has been a tough but rewarding process already. I did my undergrad in Mechanical Engineering, but this is basically the first time I've done any kind of major work on bikes. So I'm learning as I go, and buying tools and parts as I need them. My hope is that I can use this as a prototype, and keep building bikes in the future.
 
More waiting, should be getting the powdercoated parts back soon. Test fitted the tank against the seat, I think it looks pretty good!

1557700_823082114372258_1769990943_n.jpg


I also tried to get all the gas out of the tank to prep it for either stripping the paint or getting it powder coated all together. Ended up spilling some on my driveway. I doused it in kitty litter, but checked today and some of the gas had eaten away at the asphalt :eek:. Whoops! Live and learn I suppose. All future attempts to empty gas will happen over an oil pan.
 
Got the parts back from GTA Custom Motorsports:

1525394_826296220717514_114401874_n.jpg


Got all the parts coated in flat black, the pictures don't do it justice. They did an awesome job! Thanks to Johnny P, great guy to deal with.
 
Ok, so I'm back at it again, finally putting the bike back together:

I started cleaning the cushion rod and dogbones, as well as the swingarm axle:
10154206_829007750446361_333837050_n.jpg


I also hammered in the new race for my gsxr front forks. I used a combination of hammering using the old race, and a cheaply made bearing press made out of threaded rod and washers:
1977465_829007720446364_1072864319_n.jpg


I kept thinking the race wasn't fully seated, since it has a bit of a lip at the bottom of it, so I overdid it a bit and burred the edge of the race. The contact surface looks ok, so I'm hoping I don't have any problems.

Packed the top bearing:
10006482_829007737113029_422996653_n.jpg


And finally, the moment I've been waiting for since buying this bike;
1779863_829007833779686_237940189_n.jpg

Black frame with gold USD forks! Much better than before!
 
More updates!


I managed to reinstall the engine which was surprisingly easier than I thought it would be. I just lowered the frame onto the engine and slid the engine mounting bolts into place. I then lifted the bike on its stands and reinstalled the forks and the front wheel. Here's how it looks:

10155683_834165459930590_1269410657745187273_n.jpg


10245416_835083176505485_1211717335111109499_n.jpg


I also installed the radiator, with the water temperature sensor and adapter for my Koso gauge:

IMG_20140501_183419.jpg


I haven't gotten as much done because I've been trying to deal with this beast:

IMG_20140428_225119.jpg


My dirty leaky 1974 Kawasaki S3 2-stroke that I'm trying to use as my current bike to ride. The plan isn't working out as I'd hoped, since it needs constant attention and work. I had it running for about a day without problems :cool:.
 
Alright, lots more done but I've been too busy to post.


First off I had to secure the rear shock to the swingarm with the bolt from the 636. I installed it, but needed to cut the end off the bolt to fit the dogbones over top:
IMG_20140425_173254.jpg


Next I put the wiring back in, and connected a couple of wires I had cut from before. I'm still going to have to wrap some sections with something, but I'm leaving that for later. For now everything is back in place. Oh, and I also got the carburetors back in, complete with the choke cable and throttle cables.
IMG_20140507_144821.jpg


I finally have everything I need to complete the bike, except for a few mounts I'll have to build/weld myself. Received my vortex clip ons (decided to go back to clip ons for the cafe racer look), and sprockets and new chain, 15t front, 47t back for better acceleration. Here's the bike with the rear wheel on:
IMG_20140512_193050.jpg


I went with a 520 chain conversion, with Pitbull sprockets:
IMG_20140512_193110.jpg


And with the chain:
IMG_20140513_211456.jpg


I used a rivet link, but I may have to redo it. I pressed the plate on a bit too much, and I'm afraid the link is too stiff. I can move it, but it sticks more than the other links do.
IMG_20140513_211541.jpg
 
Got the tank back too, but it flash rusted after having the paint stripped. I'm going to sand it down myself, and then GTA custom motorsports will powder coat it clear for a bare metal finish that won't rust.

IMG_20140514_213948.jpg


Anyone have experience cleaning rust out from the inside of a tank? I'm thinking apple cider vinegar and then using distilled water with baking soda to flush and prevent flash rust; saw this on youtube.
 
Got the tank back too, but it flash rusted after having the paint stripped. I'm going to sand it down myself, and then GTA custom motorsports will powder coat it clear for a bare metal finish that won't rust.

Anyone have experience cleaning rust out from the inside of a tank? I'm thinking apple cider vinegar and then using distilled water with baking soda to flush and prevent flash rust; saw this on youtube.

http://www.eastwood.com/por-15-cycl...xtagsean01&utm_source=pricegrabber&utm_medium
 
Yo Brian!

FYI I did the POR-15 thing to my FJ's tank, it worked beautifully. Just ignore the instructions that come with the kit - it says to use the cleaner for 20 minutes, which is way too short. I shook the cleaner around the tank for well over an hour. Same with the drying/curing time for the sealer - they say 72 to 96 hours, but in my case it took a full week for the fresh-paint smell to go away.

GL the rest of the way man.
 
I've been busy finishing the tank, and getting some odds and ends figured out. I'm hoping to get the bike rideable by next week so I can take it to a shop where I'll be welding up a subframe and custom exhaust.

In the meantime, here's how it's looking:
IMG_20140522_140846.jpg
 
Cleaned the inside of the tank out with vinegar, and then neutralized it with baking soda and distilled water. Turned out well:
IMG_20140528_134820.jpg


This is how much rust I removed:
IMG_20140528_135958.jpg


Next I installed my front brakes, with blue spiegler ss lines. I also installed the subframe and seat temporarily, so that I can drive it once it's running to a shop, where I'll be doing the welding for the new subframe:
IMG_20140529_140657.jpg


Here's the view from the seat:
IMG_20140529_181816.jpg


I still have lots of little things to figure out: Rear brake reservoir, headlight mounts, horn mount. Basically lots of brackets that I haven't made. I don't have access to a machine shop right now, so I haven't been too involved with making all the small stuff. I'll have to figure this out soon.
 

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