Project SV650.

[oneal]

So, I found a great deal this weekend on a 2002 SV650 S.  This bike has about 10,000 miles and had been laid down at least twice.



The forks are beyond repair and the tank has several nice dings in it.  The bike had been dropped on both sides, but the left side seems to have the most damage.  The right side looks almost like new.



Over the winter, I plan to add/upgrade the following:

1) Replace the forks.  It sounds like I need to keep the stock forks on it to be superstock legal.  I'll most likely add some new Race Tech springs and Traxxion damper rods.

2) Rear Shock.  Sounds like the Penske is the way to go, but these things cost over $700... might try to find something used.  Last option would be to add a GSXR shock.

3) Steering damper.  Sounds like GPR or Pitt-Bull rotary dampers are the way to go.

4) Steel brake lines

5) Race bodywork... haven't looked into this much.

6) Rearsets.  I see a lot of bikes with Woodcraft, but these aren't adjustable.  Anybody have a recommendation?

7) Exhaust and Jet kit - This might wait until later (unless I find a cheap, used exhaust).


This should be a fun project bike.  Luckily, the engine seems to run fine.  It starts right up on the first crank every time.  I couldn't take it for a test ride because the clutch lever is completely missing.  I'll have to believe the previous own when he said there's nothing wrong with the tranny.

[rickmancc]

looks like fun project

[oneal]

So, since it was so nice out today, I took the bike out, hosed it off and removed about 5 pounds of dirt, grease and gunk.  Then, I installed a new clutch lever and took it for a quick spin around the block.

Good news is that the motor runs great.  No problems with the clutch or gearbox either.

Bad news... where's the brakes or front suspension?  Seriously, how do people ride these things stock?  I always heard the forks on the SV's were soft, but this was scarry.  To be fair, the left fork on this bike has a kink and I'm sure there's little (if any) oil in it.  But, just tapping the brakes nearly cause the front to bottom out.

So obviously my first upgrade will be to get new fork tubes, then install the correct springs and a new damper kit.  Time to search ebay.

[TGriffith]

Glad to hear your SV got a race weight reduction (although, I don't think that's typically how it's done!)  And a clutch lever for Christmas - nice.
Don't forget about Cycle Recyclers to see if they have some forks, then you don't have to pay out the wazoo for shipping.  I bet they have GSXR forks (although, if you want to race SuperStock in WERA, I guess you need stock fork tubes... but I'm no expert... hope to get into it for the first time this year myself.)

[oneal]

Parts Update:
I now have a nice pile of parts in the garage... hopefully it gets above 10 degrees soon!

- Woodcraft High Rearsets.  These look awesome, and they're the only thing I installed so far!

- Stock 2002 forks.  Got these off ebay.  They have Race Tech emulators in them and .8 springs.  I pulled one apart last night to verify the emulators were really there (they are).    I plan to completely tear them down, clean them, adjust the compression on the emulator, then install new springs.

- Fork springs.  I went with SonicSprings.  Got a set of .9's for about $100 shipped.

- Vortex Clip-ons.  The SV650s has clip-ons, but they're a little high.  Plus, you can't replace the bars on them.


Things I still need to get
- Chain & sprockets.  I plan to convert to 520.

- Rear shock.  I keep seeing ohlins on ebay for around $550, but I've read that they're too short (recommended length is around 14").  I'll probably break down and buy a Penske.

- Front brakes & lines.  Rubber lines suck!

- Bodywork & fairing stay.  Might try to get some used stuff off ebay.

[prudolf]

very cool, seems like it'll come together sooner than you may think.  I guess I'll be sure to get my hands on it soon to help you out, so I'm sure there's something I'll break for ya!   

[oneal]

New forks (w/springs, emulators), Woodcraft rearsets, Vortex Clip-ons

[TGriffith]

The project looks like it's coming along nicely.  That should keep you busy for the rest of winter.  First race is at the end of April with FastTrax.  (I think Andy mentioned you can get an earlier start with WERA at VIR around March 19).  I picked up an old SV650 (Race ready) from a friend of Aarons, and will be doing the FastTrax race at Nelson Ledges at the end of April.  Should be a blast!

[oneal]

Awesome.  I'll be with you at Nelson in April... assuming I get the bike done 

[TGriffith]

For those of you that prefer pictures over reading (especially when it comes to safety wiring) I hope these pictures help you out.
These are all the pictures of the safety wiring on my SV650 (I hope I didn't miss any - let me know if I did).
FYI - some bolts are flat-out safety wired.
Some only need a dab of gasket maker,
and some hose clamps need to be safety wired.
Click here for the pix

[TGriffith]

FYI - if anyone needs to order fork seals, you can get them from Traxxion - they told me the size you need for a 1999 SV650 is:
FSO 41x53x8/9.5
(You can also order from DennisKirk.com)

[oneal]

Penske 8983 shock installed.  Thanks to Paul, Tom and beer


Hotbodies bodywork fitted


Kirby inspecting my safety-wire job... and a dirty rag

[oneal]

So I just have to finish up the little stuff now.  Tires, brakes, final safety wiring, etc.

When mounting the tail, I realized that the rear brake reservoir and the voltage regulator are in the way (they hang off the right side of the subframe).  Any suggestions on where you can mount those things?  I'm sure the regulator can be zip-tied to the inside of the subframe, but the brake reservoir is a mystery.

[oneal]

Just took the SV for a spin around the block.  It's amazing what suspension can do! 

[oneal]

Painting in progress...