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

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

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)

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)

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)

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