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Old 05-10-2017, 07:37 PM   #1
snowdave
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Super Cheap Gen2 Track Bike

I recently picked up a 2005 SV650 for just a few hondos since it was crashed, the seller couldn't get the engine running and decided to swap the title for a junk certificate. I'd say they were stupid on the last point, but it is law in some states based on repair estimates for resellers.



If someone has interest in copart or crashedtoys, I can likely put together another thread on the experience.

So, what was wrong:
Dented tank
Non-running engine
No gauges
Unknown mileage
Smashed radiator
Bent handlebars
Cracked front fender
Scratched all over
Broken turn signals
Smashed headlight & mounts
Bent shifter
Cracked front master cylinder
Missing side covers
Junk Certificate (getting a street title would be VERY difficult)

I paid my money and drove a couple hours to pick it up. I was pleasantly surprised when getting it as I notice it had power, was not missing the ECU and the clutch cut-out was unplugged. I not only had hopes of an easy fix, but perhaps even putting it on the street.

Once home, the teardown began, initially to get the bike running while researching title options. Plugging in the clutch cut-out resulted in the starter turning.....hope! No fuel pump noise, it too was unplugged. Now I was suspicious as this had to be on purpose. Sure enough, there was surface rust in the tank. $10 of vinegar, a couple days and a pump cleanout later it fired right up and ran great. Next was driving, so all controls came off and a $20 set of Chinese clip-ons were ordered. Still waiting on these, but I expect it will drive fine. I bent the radiator back to something near a rectangle and think it will work fine for now as it does not leak.

In parallel, I fully researched the title options and although there are some (a titled frame, VT registration in 3 years, states that allow rebuilds, states that don't issue junk certs, etc) I decided I would just continue with my initial plan....a super cheap track bike.

That brings me to today. I removed the tail section so I could take the lights off and am left with 3 holes (2 for tail lights and 1 for the fender). I plan to mold some fiberglass to the openings. Since I already had the material, I only needed $4 worth of resin hardener. If this works, I may even make a rear seat cowl....heck, it's free at this point.

So, cost to date:
Bike - $400
Fees - $280
Clip-ons - $20
Vinegar - $10
Hardener - $4
Total - $714 (my labor is free :-)

I plan to use this thread to document further work and hopefully track days. I would love to hear any ideas on ways to keep this project as cheap as possible.

I have ~1 year until I get to the track as I have a personal weight loss goal before I go buy or even rent leathers. I am well on my way from training for harescrambles, but realistically this bike won't see the track until 2018.
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Old 05-16-2017, 03:20 PM   #2
snowdave
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Re: Super Cheap Gen2 Track Bike

A few bits of progress in the last couple days:

1. Clip-ons arrived. No complaints for $20.
2. I decided on a Chinese Speedo ($33):

3. I am nearly ready to lay the glass
4. The front master cylinder and clutch adjustment dial may need some TLC

Grand Total - $747
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Old 05-17-2017, 09:20 AM   #3
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Re: Super Cheap Gen2 Track Bike

Quote:
Originally Posted by snowdave View Post
A few bits of progress in the last couple days:

1. Clip-ons arrived. No complaints for $20.
2. I decided on a Chinese Speedo ($33):

3. I am nearly ready to lay the glass
4. The front master cylinder and clutch adjustment dial may need some TLC

Grand Total - $747
Hope the cluster install is not a real PITA for you. I used it on my CBR F3 and it took a lot between me and another CBR forum member to get the tach going. Since it was a track bike never bothered to put together the speedo wiring...
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Old 05-17-2017, 10:51 AM   #4
snowdave
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Re: Super Cheap Gen2 Track Bike

I found this site and install instructions online:

Not a link............img.banggood.com/file/products/20150226035204English Manual of SKU192807.doc

Sorry, no link as my post count is not high enough yet ;-)

I have also seen a few threads on installing them that did look like a PITA. As you said, I only really care about RPM and maybe a shift light, so I am hoping I can muddle through it. A Suzuki dash would cost 5X as much as it seems they contain the odometer and can be used to fraudulently lower mileage (hence the high price).
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Old 05-17-2017, 04:12 PM   #5
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Re: Super Cheap Gen2 Track Bike

It's going to be a track bike. Either run without a cluster or find one with missing segments. Mine hasn't crashed very well so about the only segments that still light up consistently is the temp.

I personally wouldn't bother with a Chinese cluster. When the bike goes Baap Baap Baap Baap as you accelerate, it's time to shift.
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Old 05-18-2017, 09:19 AM   #6
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Re: Super Cheap Gen2 Track Bike

Also, before you go balls in with this build, maybe you should consider just buying a track bike out right form the race forums, like 13X forum. The money you will spend on the bike, you will be able to get a much better sorted out vehicle. If you spent $2000 on your bike you could get a bike with $4/$5 grand of upgrades there... I did two builds before I decided, I would never build a track bike again...
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Old 05-18-2017, 02:29 PM   #7
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Re: Super Cheap Gen2 Track Bike

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Originally Posted by SabotageR1 View Post
Also, before you go balls in with this build, maybe you should consider just buying a track bike out right form the race forums, like 13X forum.
I completely agree with you. A fairly well sorted/upgraded track bike can be had for $2-3k from what I have seen. The costs of tires, suspension, fairings, etc will exceed that in no time.

Having said that, my goal here is to take a very cheap bike and enjoy some track time with it. If I really enjoy it, I will likely look at trading up. If not, my investment will still be pretty minimal. This is exactly why I am looking for budget suggestions on track prep. Besides, I like to tinker. Think there are at least 4 bikes in pieces in my garage at any given time.
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Old 05-18-2017, 04:22 PM   #8
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Re: Super Cheap Gen2 Track Bike

As long as you dont invest in expensive aftermarket suspension and the like then theres no reason why you wont end up with a cheap track hack. Esp if you are new to track riding?
I'd spend some dosh at the end on some good quality fresh rubber and a set of sintered front brake pads.
Whats the exhaust system like and the chain and sprockets?
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Old 05-19-2017, 05:40 AM   #9
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Re: Super Cheap Gen2 Track Bike

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Originally Posted by Kiwi Rider View Post
Whats the exhaust system like and the chain and sprockets?
The bike is in surprisingly good shape. Tires are new, chain & sprockets look good. Even has a Lithium battery.

The exhaust is completely stock and looks like it weighs a ton. I have reasonable fab abilities so I may see if I can cobble up something lighter, and perhaps higher. I need to be careful about upgrades that will require refueling though. I have not researched what is available to tune the EFI (tuneboy or similar?), but did read it is a pretty basic system so I would imagine it won't adjust for exhaust changes.
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Old 05-19-2017, 05:43 AM   #10
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Re: Super Cheap Gen2 Track Bike

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Esp if you are new to track riding?
Yes. I am currently racing hare scrambles, fooled around on MX track and have run many backroads on sport or sport-touring bikes, but never been on a track that wasn't dirt. That is part of the reason I figure a very basic setup will be fine while I learn.
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