2006 SV650 Lessons Learned

[Deleted member 50930]

Hi members,

Nature of accident: 50-60 km/h and hit a barrier. I'm so lucky to be alive without broken bones

• Excellent forum: Suzuki SV650 Forum: SV650, SV1000, Gladius Forums
• Resource for finding part numbers: Suzuki Parts House: Buy OEM Suzuki Parts & Accessories
• Dealt mostly with Rob from Tri-City Cycle & Sport Inc for OEM parts
• Definitely get the service manual so you have torque spec values
• You must have torque wrenches and a good selection of Allen keys and wrenches.

Total time spent to do all this? A Saturday and Sunday with my friends
Total Cost for parts excluding plastics: ~$1000
Total Cost for new tools: Motorcycle stand from Amazon Canada ~$100

The most difficult part: Finding parts to fix the fork and cutting the piping for the Racetech springs

Section 1: Fork Rebuild with Racetech springs

2006 Suzuki SV650 Front Damper | Babbitts Suzuki Parts House

Shop online for OEM Front Damper parts that fit your 2006 Suzuki SV650, search all our OEM Parts or call at (231)737-4542

www.suzukipartshouse.com

Fork Rebuild resource1: bluepoof bikes - changing fork oil
Fork Rebuild resource2: http://vividphase.com/fork_guide/Changing_the_Springs_and_Oil_in_a_SV650.doc

• Bought inner fork tubes from eBay (aaamotorhk) but another option is Frank's Forks (Franks Forks)
• The gen2 SV650 have ABS and non ABS part numbers. They are interchangeable, get whichever is cheaper and don't forget to buy the washer
• You should definitely have a table vice grip, lots of rags and lots of brake cleaner
• SVrider forum made a big deal about finding a 8mm but it wasn't that hard, I used my 8mm hex bit socket

Part #: 51153-08D00 or 51153-01H00 (Fork Seal)
Part #: 51571-47D50 or 51173-01H00 (Dust Seal)
Part #: 51148-36011 (Crush Washer)
Motul 15W Fork Oil
Racetech springs

Section 2: Rad Replacement

2006 Suzuki SV650 Radiator Hose | Babbitts Suzuki Parts House

Shop online for OEM Radiator Hose parts that fit your 2006 Suzuki SV650, search all our OEM Parts or call at (231)737-4542

www.suzukipartshouse.com

• Lesson learned: There are different rad fans for the gen2 SV650
• Purchased coolant from KW Honda - Motorcycle / ATV / Side by Side / Power Equipment
• I bought a China rad and modified the rad fan mounting location. The china rad was also wider which was fine for me.

Section 3: Clutch Pedal Replacement

2006 Suzuki SV650 Gear Shifting (Model K3) | Babbitts Suzuki Parts House

Shop online for OEM Gear Shifting (Model K3) parts that fit your 2006 Suzuki SV650, search all our OEM Parts or call at (231)737-4542

www.suzukipartshouse.com

• Lesson learned: Find a used entire clutch pedal assembly
• Tried ordering a China one and had one heck of a time removing the c-clip from the stock one without damaging it
• For the c-clip I used a very thin flat head screw driver

Section 4: Front Wheel Removal

2006 Suzuki SV650 Front Wheel (Sv650ak7/Sak7) | Babbitts Suzuki Parts House

Shop online for OEM Front Wheel (Sv650ak7/Sak7) parts that fit your 2006 Suzuki SV650, search all our OEM Parts or call at (231)737-4542

www.suzukipartshouse.com

• Followed various youtube videos on front-wheel removal

Section 5: Handlebar Replacement

2006 Suzuki SV650 Handlebar (Without Cowling) | Babbitts Suzuki Parts House

Shop online for OEM Handlebar (Without Cowling) parts that fit your 2006 Suzuki SV650, search all our OEM Parts or call at (231)737-4542

www.suzukipartshouse.com

• Fortnine has black handlebars for ~$20-$100 but the downside is they are supposedly too long and you need to drill holes
• If you get a aftermarket handlebar the OEM handle bar weights might not fit either
• OEM handlebar is ~$100 and will just fit
• OEM handle bar weight bolt p/n is 02122-0670b

Section 5: Subframe Replacement

• Waiting for the mechanic to inspect the bike first
• Obvious damage on the subframe that I can see is the broken rad holder thing

Section 6: Front Windshield Replacement

• Ordered one from AliExpress

Section 7: Deal with all the busted plastic

• Cosmetic and very expensive
• Front Fender
• Seat Tail Cover
• Headlamp cover LH and RH
• Dents in the gas tank

Still to do include ...

• See if windshield fits
• Deal with the handlebar
• Take it to the mechanic for a professional inspection