Reviving my í01 Curvy (Yes, I know thatís redundant) - Page 6 - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

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SV650 Gen1 (99-02) Tech Info, advice or questions specific to the 1999-2002 model SV650.

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Old 08-19-2019, 02:22 PM   #51
DemonRider
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Join Date: Jul 2008
Location: Northern VA
Bikes: '01 SV650S, '05 GSXR 750
Miles Kms: SVS 21,000, GSXR 5,500
Posts: 90
Re: Reviving my í01 Curvy (Yes, I know thatís redundant)

Sorry to keep posting problems and making this thread so long, I'm sure everyone is sick of me posting my issues and long winded posts! I try to give as much information up front so people can understand what the issues are.
And I'm close to the finish line!

So, new day, new problem. I was sure my original petcock was pretty gummed up and the filter disintegrated when I tried to clean it. They are fairly cheap, so rather than get a rebuild kit I just ordered a new one (again from Ebay). The new petcock looked fine except the fuel and vacuum line outlets come out from the left side (when looking at it from the front,see the red box in the 1st pic showing where the fuel line comes out of the new unit), rather than towards the front like the stock unit. I was able to remove the vacuum line and rotate it 90 degrees like the stock one, but the fuel outlet is cast in with the body, so no way to rotate it.

I didn't think it would be an issue so I figured it would be fine, until I just tried to remount the tank (The KBS lining worked great, btw!). The fuel outlet is also a little bit larger than the stock one, so I ended up ripping it when I first installed it - I only realized after starting the bike and saw fuel pouring all over the (now getting hot) engine and floor! I thought I was screwed because I have put some gas in the tank and I panicked, thinking there was no way for me to stop it from all draining out! Luckily I remembered that the fuel only flows when there is a vacuum in the vacuum line, so I quickly pulled the hose off and it stopped the flow. Shew! At least I know that the petcock is working as intended! I bought a piece of beefier fuel line from Advanced Auto and spliced it in with an inline fuel filter. All good, right?

The issue is that when lower the tank, the fuel hose going to the fuel pump fouls against the cylinder head. See pics below showing the original petcock, the new one installed (the fuel line is highlighted yellow, the red circle in the 2nd pic is where the fuel line comes out of the stock unit). In the last pic you can see the fuel line bending upwards as I lower the tank. It doesn't bend enough to pinch it, so the bike still runs. The question is how hot does the cylinder head get, and I worry about the vibration of the engine debraiding the fuel line after probably not too long. Any idea for solutions?

Stock


New unit in raised postion


New unit when lowered. Note fuel line hitting cylinder head and bending upward
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Old 08-19-2019, 04:07 PM   #52
DemonRider
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Join Date: Jul 2008
Location: Northern VA
Bikes: '01 SV650S, '05 GSXR 750
Miles Kms: SVS 21,000, GSXR 5,500
Posts: 90
Re: Reviving my í01 Curvy (Yes, I know thatís redundant)

OK, a little bit of a false alarm there. After further inspection, the fuel outlet is in fact out of the front of the petcock casting and not a part of the casting. It's just a 90 degree elbow plugged into the casting. I was able to rotate it upwards a good 75 degrees (I rotated it as far as it would go until the fuel line was against the tank wall), such that the fuel line clears the cylinder head handily. Connected everything back together and fired her up an saw a very small leak from the fitting. I pressed it back in with some channel locks, ran it for a few minutes and the leak is gone. I'm going to call that a problem solved!
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Old 08-19-2019, 06:55 PM   #53
DemonRider
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Join Date: Jul 2008
Location: Northern VA
Bikes: '01 SV650S, '05 GSXR 750
Miles Kms: SVS 21,000, GSXR 5,500
Posts: 90
Re: Reviving my í01 Curvy (Yes, I know thatís redundant)

So the last step was to desnorkel the new air filter and put the air box back on. Got it done and took her out for a couple of shake down laps around the block. First ride on it in almost ten years! Brakes are a little bit squishy - probably could use some new front pads and some more bleeding. Next I'll check the fork seals. I put a Ohlins rear shock, Traxxion Dynamics drop-in damper kit with emulators, new Racetech springs, and 20W fork oil in it in '08. Probably could use new oil. But I forgot how grunty and fun this bike was!
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