SV650 Winter Project - Wrist Twisters
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post #1 of 50 Old 02-10-2014, 08:02 PM Thread Starter
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SV650 Winter Project

I've mentioned this project a few times in other threads, and decided it's about time I start providing a little progress on this. Fortunately, putting a GSXR front end on an SV650 is much more straightforward than the RC51 swap on a 919, otherwise it might be too much for me! It's been done a lot, so I had good confidence in being able to sort any issues I might run into.

I've been bad about getting pics for each step, but have a few that I can share on progress so far.

Here's the poor bike, already stripped down and suspended so I could remove the triples:

Please ignore the mess....I'm working on it!

Top and bottom of head tube with races removed:



Old SV triples left, new GSXR triples on the right:


The new triples are over 2.5 lbs lighter than the old ones!

Old SV clip-on next to TL1000 clip-on:

I originally bought GSXR clip-ons, but they didn't sit high enough.

My work over this past weekend: custom steering stops! They're not pretty, but they work :P


Installed on the bike:


In action:



Here are the forks that will be installed, maybe tomorrow. '07 GSXR 600:


The shock that will replace the worthless stock (honestly, the SV shock is really bad). An '06 Kawi 636 shock:


And, finally the wheels. They are at the powdercoater to get a silver finish similar to the OEM SV wheels. They were in great shape, but it would've just been too much blue to use them as is!


Yes, I'm putting the GSXR rear wheel on the SV, thanks to some help from TWF Racing.

I'm also updating the voltage regulator (R/R) thanks to an iffy OEM unit. Switching it out for a MOSFET unit off a CBR600RR. Now I just need to find some Yamaha parts to round out the composition of this bike

Will continue updating as I make progress. The rest will hopefully go pretty quickly.

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #2 of 50 Old 02-10-2014, 09:09 PM
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Awesome! Keep us posted! I swapped in a GSXR shock into my little SV and it changed the bike completely! So many good threads on SVrider about USD conversions and mods in general. If you have any questions, PM a guy named kvesi122 on SVrider since he just did the exact same conversion to his 1st gen SV.

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post #3 of 50 Old 02-10-2014, 09:35 PM
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that is one thing i love about the SV650... SO MUCH aftermarket / easily swappable parts. and that vtwin sound... mmmmm

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post #4 of 50 Old 02-10-2014, 09:40 PM
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Nice! Can wait to watch this build.

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post #5 of 50 Old 02-10-2014, 09:51 PM Thread Starter
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Originally Posted by filipinoaviator View Post
If you have any questions, PM a guy named kvesi122 on SVrider since he just did the exact same conversion to his 1st gen SV.
Cool, will do. SVrider is where I've gotten a lot of my info so far.

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post #6 of 50 Old 02-11-2014, 08:56 AM Thread Starter
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I should probably change the title since it is a little more than a front end swap; maybe just SV650 winter project.

Anyway, does anyone have suggestions for a different slip-on exhaust? The stocker is heavy and works too well. I want to hear it sing! Louder, but not obnoxious would be nice

Stuck at home today due to workplace closure (weather), so will be playing some more. Wish I had the wheels back!

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post #7 of 50 Old 02-11-2014, 09:03 AM Thread Starter
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Oh, and if anyone has a line on some Gen2 SV650 intake cams, let me know! I can get them new for ~$300, so really want to find some used, as I've already invested a bit in the upgrades. Gives a nice little HP boost

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #8 of 50 Old 02-11-2014, 09:36 AM
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Quote:
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I should probably change the title since it is a little more than a front end swap; maybe just SV650 winter project.
Done.

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post #9 of 50 Old 02-11-2014, 09:41 AM Thread Starter
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Excellent. Thanks!

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post #10 of 50 Old 02-11-2014, 11:43 AM
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Give us a little more info on the SV? I'd love to buy one and run it at the track.



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post #11 of 50 Old 02-11-2014, 01:17 PM Thread Starter
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A little progress today since I'm sitting at home

I have the top triple, clip-ons, and forks mounted now





I have a GSXR clutch perch I'm going to put on; the SV perch doesn't leave enough room for the controls on the new clip-ons. Plus, I want to be able to buy matching levers anyway. I already have a Pazzo brake lever I got for cheap on ebay; I didn't realize that they only sell them in pairs, so have been on the hunt for a matching clutch lever for the last couple of months. Buying some cheap CNC levers on ebay to do the job in the meantime.

I got my steering stops pretty close to where I wanted them to be. Here is the point on each side where the forks come closest to hitting (top radiator mounts):

Left


Right


Still plenty of room before the clip-ons hit the tank. I need to shave just a little off the left stop to allow the steering lock to work...I can almost engage it.

I have a black plastic front fender that came with the forks that I was going to paint, but looking at paint prices, it will probably be cheaper to find the right color fender on ebay. I'm thinking that, or carbon-fiber wrap the one I have, because I doubt I can get a close enough match to the Suzuki blue to make the Mrs. happy...it has to be right!

More to come. I should have wheels this week!

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #12 of 50 Old 02-11-2014, 01:23 PM
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These would look nice on there... interested?



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post #13 of 50 Old 02-11-2014, 01:41 PM Thread Starter
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Quote:
Originally Posted by crakerjac View Post
Give us a little more info on the SV? I'd love to buy one and run it at the track.
I'm no expert by any means, but I'll give you my thoughts on it. You can easily find the specs for it, so I won't go into those.

What I like about it:
Good torque; don't have to get high into the revs to get decent power. Not as high-strung as the 600 inline fours. Of course, the 600's have a higher peak HP (I think the Gen 1 SV650 is ~65HP, Gen 2 is ~74). Some jetting and other simple mods can boost the Gen 1 a little.

Fairly lightweight, and easily flickable. With the mods I'm doing, it will be even lighter.

Even with the stock suspension, it handled pretty well in the corners. I can't wait to see how it does with a decent shock and good forks!

I don't know what current prices are, but ours is almost 13 years old, so you should be able to find Gen 1s (99-02) fairly reasonably priced. The Gen 1s are carbureted, whereas the newer ones ('03+) are fuel injected.

If you were to buy an SV with the intent of doing this swap, it is actually easier on the '03+ (Gen 2) SV's, because they use the same steering head bearings as the GSXRs.

I haven't done a trackday yet, but am seriously thinking about it; that's part of the justification to myself for doing this I'm thinking this would be a hoot on the track once the suspension is properly setup.

Not sure if that's what you were looking for, so let me know if you have any specific questions.

Stu

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post #14 of 50 Old 02-11-2014, 01:50 PM
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Quote:
Originally Posted by crakerjac View Post
Give us a little more info on the SV? I'd love to buy one and run it at the track.
https://www.wristtwisters.com/forums/...650-32368.html

Would make an incredible track machine. After changing the rear shock and putting ATF in the forks, the thing cornered like a DREAM. Coupled to the Michelin Pilot Powers, it was on rails thru the twisties. Dammit, I swore I wouldn't miss the SV

I sold mine for $1600 in less than 1 day with nice tires, new battery, Gixxer rear shock, freshened forks, rejetted w/ full Micron exhaust. I sold it far too cheap. But, I paid off my truck, so I still sleep well at night.

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post #15 of 50 Old 02-11-2014, 01:51 PM Thread Starter
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Originally Posted by selztoad View Post
These would look nice on there... interested?


Nice! Were it specifically my bike, I'd jump on those. My wife wants to keep a stock look, to the extent possible. Not sure she'd like numbers on her bike, of course that could change if we start getting to the track!

Thanks for offering. Did you ever get your bike sold?

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post #16 of 50 Old 02-11-2014, 03:41 PM
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I was actually curious about your SV. Did you purchase it recently with these mods in mind? What other mods do you have in mind?
I've done a lot of reading about the SV especially for track use... But if I bought another bike that would be a decision my wife said she will make me regret.



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post #17 of 50 Old 02-11-2014, 03:46 PM Thread Starter
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Originally Posted by crakerjac View Post
I was actually curious about your SV. Did you purchase it recently with these mods in mind? What other mods do you have in mind?
I've done a lot of reading about the SV especially for track use... But if I bought another bike that would be a decision my wife said she will make me regret.
Ahh, okay. My wife bought the bike new in 2001. She rode it much more frequently back then, but stopped commuting on it 8-9 years ago; since then, it's mainly been an occasional weekend ride and that's about it. I'm trying to give it a little refresh to maybe get her more interested in riding again. Plus, I'd love to get her to a track day

Until now, it's been all stock.

Forgot to add: If it were strictly for the track, I'd probably get an aftermarket shock. The 636 will be an improvement for sure, but probably not good enough for a dedicated track bike.

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post #18 of 50 Old 02-12-2014, 09:47 AM Thread Starter
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Electrical

Slow day here, so even though electrical stuff isn't that exciting, I'll give an update on where I got to last night

In general, the first gen SVs have a couple of issues with the charging system. The first, which I didn't mention in my original post, is the gauge of the wire in the wiring harness coming from the R/R, and the length of it's path before it ever reaches the battery. To give an idea of this, here's a shot of the wiring harness connectors that plug into the stock R/R:

16 gauge at best; I haven't cut it to verify.

The solution, which I've seen posted on several sites, is to not connect the R/R output to the wiring harness, and instead have it go directly to the battery using 12 gauge wire. Using recommendations from SVrider, I bought all of the connectors from Eastern Beaver and made a harness that plugs into the output of my new R/R and goes directly to the battery (fused). With the larger gauge and the short run it should be much more efficient. Here's what it looks like:

The black lead will go directly to the battery, and the red goes through a 30A fuse (the covered connector to the left in the pic).


The second issue is the R/R itself. Over time, the first gen R/R has been known to fail. It's not a very efficient unit and generates a bit of heat; I'm guessing that is a large factor in the failures. While ours is still good, I'm going to replace it now so that it doesn't leave us stranded later. Based on a little reading, it seems the FH008 unit from a CBR600RR is an excellent replacement unit. I got one on ebay for a decent price:


Next to the OEM unit:


In the pic, I've already cut off the connectors from the new unit and installed water resistant connectors. Another good thing about using this model as a replacement: it bolts right up to frame just like the stock unit



With everything connected, but minus the battery


The wiring harness R/R connection is still hanging there. I'm just going to tape it up for now and tie it to the frame.

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post #19 of 50 Old 02-18-2014, 06:44 PM Thread Starter
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Wheels!

Finally have them back. I couldn't get exactly the color I was looking for, but I think they'll look okay on the bike. Unfortunately the PC guy didn't listen very well when I explained where not to coat it, so I'm having to do a little cleanup

Almost ready for bearings/tires:


I picked up the blue 90 degree valve stems from Heli a while back (thanks again!); I think they'll be a good compliment once everything goes back together

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post #20 of 50 Old 02-18-2014, 06:56 PM
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Very nice. That's almost the same color ones I have. I usually only like black rims but I like that shade of silver.

Spoiler:

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post #21 of 50 Old 02-18-2014, 07:01 PM Thread Starter
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Shocking... ;)

I spent an evening last week installing the Kawi shock. It's a worthwhile upgrade if on a budget (I think I paid $40 shipped).


The Kawasaki shock (from a 636) has the red spring, the stock SV is the yellow:



Notice any difference? Yuck. And you think the 919 shock is bad? lol

New(er) shock mounted. The reservoir and the battery are trying to use the same real estate....


I've got to push the battery box back a bit to make space.


I've got the bolts, and just need to finish making spacers to hold it back out of the way. I'm considering getting a lithium battery to give me more space to work with.

While I had it apart, I pulled the sleeves out of the suspension linkage and forced new grease into the needle bearings. Also cleaned up the whole assembly; it was black from road grime, grease, etc. Nice and pretty for now

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post #22 of 50 Old 02-18-2014, 07:10 PM Thread Starter
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Very nice. That's almost the same color ones I have. I usually only like black rims but I like that shade of silver.
Thanks! Originally wanted to match the SV OEM wheels, but I like the way these turned out. Sunlight really brightens them up.

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post #23 of 50 Old 02-18-2014, 07:36 PM Thread Starter
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D'oh!

Clearance issue! Radial master won't fit; it hits the dash on a left turn.



Looks like I'll be sticking with the original M/C; at least for now.

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post #24 of 50 Old 02-22-2014, 10:19 AM
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Making the SV into what it's always deserved to be!
I run a lithium battery in the 9er and love it. only like $149 locally for a shorai with way more amps than the stock battery.

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post #25 of 50 Old 02-23-2014, 06:59 AM Thread Starter
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Originally Posted by Delraco View Post
Making the SV into what it's always deserved to be!
I run a lithium battery in the 9er and love it. only like $149 locally for a shorai with way more amps than the stock battery.
Yep! It was obviously built at a price point, but it worked well. Really itchin' to get it out on the road with the upgrades!

I need to take a more serious look at the shorai.

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post #26 of 50 Old 03-03-2014, 07:57 PM Thread Starter
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Speed sensor

The SV OEM speed sensor is mounted on the front axle, and reads a ferrous cylinder, driven by the front hub, that provides 4 pulses per revolution. I found the solution on svrider, which is to fasten 4 strong magnets to the front brake rotor, 90 degrees apart, then mount a sensor on the fork leg such that it can register them as the wheel turns. There are 12 buttons on my rotors, so I used JBweld to hold a rare-earth magnet in every third hole.

I got the hall effect sensor from Newark electronics. For the cable to connect to the bikes harness, I bought the proper connector from Eastern Beaver, and made my own out of a light duty, grounded power cord I had laying around I just didn't like the idea of cutting the stock cable off of the old sensor. Plus, this way maybe I can get some money for the OEM unit on ebay




And mounted, using my special, custom made, hall effect sensor bracket


Amazing what you can do with a torch, a hammer, and a vice

Front view; you've got to get it pretty close to have it read right


Fortunately, the front fender will hide this when it's mounted.

It seems to work based on a quick test, though I won't know that it is right until I get it on the road and have something to compare it to.

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post #27 of 50 Old 03-03-2014, 08:14 PM Thread Starter
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Tires/bearings/battery box

Pretty self explanatory. The rims got all new bearings, and I got the PR2s mounted. I did the tires just using spoons and rim protectors. It wasn't as hard as I though it'd be.


Getting the bearing out of the sprocket carrier was tough, but I'm glad I got it replaced. No idea how many miles the original had, so best for peace of mind.


Really naked:


Looks better with wheels/tires:


As you can see in the pic, I got the 520 chain installed too. Yes, I'm not organized...

I had to modify the battery box to not interfere with the shock protector (not really a hugger, so not sure what to call it). It was rubbing right at the front of the box, just past the edge of the battery.

Before:


After:


I tried to cut only as much as I had to. This gave me the clearance I needed.

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post #28 of 50 Old 03-03-2014, 08:29 PM Thread Starter
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All I've got left to do is finish installing and bleeding the front brakes, and button her up and I'm done. Should be on the road this weekend, weather permitting

The only reason the brakes aren't done yet is the place I bought my Galfer lines from sent me a Gen2 SV650 kit. For some reason, the Gen1 has a different thread pitch for the MC banjo bolt. I got a slight refund, but had to source the proper banjo, which I just received.

Here's how she currently stands, on her own two wheels




Now has a 180 rear tire (thanks to the GSXR rear rim). Quite a difference from the stock 160!



It fits and has the necessary clearance, but not by a lot!

It's going to feel like a completely different bike. Hopefully in a good way!

I'll post a final update when she's complete.

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #29 of 50 Old 03-04-2014, 08:27 AM
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Gladiator FTW!!!

Oh, bike looks good, too!!!

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post #30 of 50 Old 03-04-2014, 12:27 PM Thread Starter
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Gladiator FTW!!!
Yeah, another project. Trying to clean up the garage...

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post #31 of 50 Old 03-04-2014, 02:00 PM
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Yeah, another project. Trying to clean up the garage...
Keep watching Slickdeals for Gladiator stuff - put in an alert. I've never paid more than 60% retail price for my stuff, most has been around 30-40%.

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post #32 of 50 Old 03-04-2014, 03:46 PM Thread Starter
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Lol, yeah, I frequent SD. That's where I found the deal on the cabinets I have (Sears sale). I do need to set an alert for this stuff, though.

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post #33 of 50 Old 03-04-2014, 04:43 PM
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That SV project is looking great! Should be quite the weapon once you get it dialed in.

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post #34 of 50 Old 03-09-2014, 10:04 AM Thread Starter
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Wife and I took a ride yesterday, after getting the sag set. Overall she likes the upgrade

She did give some good feedback on things I need to tweak (compression is a little firm, turn-in is slower). I took it for a spin afterwards and agree, so will be playing with it today.

Also learned that the speed sensor appears to be reading all of the rotor buttons, so reading extremely high. Oops!


Attachment 51809

Sorry for the bad pic. Didn't realize how much sun glare there was.

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post #35 of 50 Old 03-09-2014, 10:06 AM Thread Starter
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Oops, here's the pic.

ForumRunner_20140309_120539.jpg

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post #36 of 50 Old 03-09-2014, 10:35 AM
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Oops, here's the pic.

Attachment 51833
Nice job, she looks great!

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post #37 of 50 Old 03-12-2014, 09:43 AM Thread Starter
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Moved the speed sensor out another 5 mm or so, and now it reads correctly.

The miles pile up fast when the speedo reads 150+

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #38 of 50 Old 03-12-2014, 12:50 PM
Ian
 
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Try and pick up the edge of the rotor button with the sensor, if you use the ceneter of the button it counts the void and really throws things out of whack.

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post #39 of 50 Old 03-12-2014, 05:22 PM Thread Starter
GLG-20
 
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Thanks! My goal was to actually just pick up the magnets in every third button, and not the buttons themselves. Just had to get the distance right, and it seems to be right now.

I guess with a speedo-healer I could have just used all of the buttons and not worried about the magnets....but I'm cheap!

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #40 of 50 Old 03-20-2014, 08:15 PM
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Does the bike now turn in slower with the 180?

07' 919 - In Progress

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