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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 01-26-2009, 07:59 AM   #31
2001chromo
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Re: Suave's GSXR Swap Pictoral Guide.

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Originally Posted by Jan Zoellner View Post
I wanted to do it this way, too. But with the very thin wall thickness of Zorans bearing it actually worked worse then tapping it in, so YMMW.

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I tried with a headset bearing press the first 3 times and it kept going in too crooked.

I ended up just gently tapping it in with a mallet and the old race on top, this ended up working perfectly.

Then I did the bearing press just to make sure it was bottomed out and parallel.
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Old 01-26-2009, 12:07 PM   #32
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Re: Suave's GSXR Swap Pictoral Guide.

Another fix i used was after you have tapped the race in, place the bearing in and the dust cover and top nuts and lower triple and tighten them down super hard then back off of them to normal tightness. Seems to have helped center it a bit.
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Old 01-26-2009, 12:13 PM   #33
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Re: Suave's GSXR Swap Pictoral Guide.

ghetto subscription! looks like a great one to follow. Nice pic catalog.
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Old 01-27-2009, 12:00 PM   #34
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Re: Suave's GSXR Swap Pictoral Guide.

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Originally Posted by SuaveNotion View Post
Another fix i used was after you have tapped the race in, place the bearing in and the dust cover and top nuts and lower triple and tighten them down super hard then back off of them to normal tightness. Seems to have helped center it a bit.
I would never do that, you could put indentation in the race and /or put flats on the rollers. You should never over tighten thrust bearings.
I've seen the damage when people do this.
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Old 01-27-2009, 06:35 PM   #35
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Re: Suave's GSXR Swap Pictoral Guide.

Finally! My upper triple came back from the machine shop. I had them place a piece of aluminum cut up to fit the recessed areas of the top triple. Then I had them tap and drill it so that the bolts would work. Looks really good...



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Old 01-28-2009, 01:29 PM   #36
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Re: Suave's GSXR Swap Pictoral Guide.

Interesting way to do it.
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Old 01-28-2009, 05:20 PM   #37
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Re: Suave's GSXR Swap Pictoral Guide.

Ok so once you have your triple with mounted gauges and risers if you're doing handlebars, you can go ahead and screw the keyhole back on the triple using that stupid security torx tool.



Once that has been done, pull all of the cables and wires from the controls and clutch back through in between the forks and neck.


Then you can go ahead and put the triple back on the bike.



Tighten the pinch bolts and top nut with washer once you have lined up the forks up top.



Ok now I made the mistake of putting the handlebars on first and then trying to put the controls on...WRONG.

Slide the left mirror on and screw in the left control using that stub as the guide.

Something like this...



Same goes with the right controls.


So then you can tighten the handlebars down once you have them where you want them.
Now you can put on the brakes using the 2 screws on each side.



So it should look something like this...

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Old 01-31-2009, 03:20 PM   #38
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Re: Suave's GSXR Swap Pictoral Guide.

The end is near!
My spacers came today which means i can finally get the tire on..


Remember: If you just buy yourself a busa axle and wheel then you will not need spacers for this. Unfortunately I didn't know this until after I had bought the wheel and axle...
Anyway, take off the rotor bolts and remove the rotor so you can put your spacers on them.



Then pull out one of your brakes so the wheel goes on easier, and slide the axle through wheel and the axle spacer.


You can see the spacer here although its kind of a crappy pic...


Now tighten the axle down to snug and then tighten the pinch bolts. Then you can finally get the thing off the jack.




All I have left is to make the speedo work and find some way to mount the headlight. Hopefully the Wisconsin weather will have at least gotten above freezing...
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Old 02-03-2009, 03:05 PM   #39
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Re: Suave's GSXR Swap Pictoral Guide.

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Hopefully the Wisconsin weather will have at least gotten above freezing...
My heater went out last night. Having the brother-in-law stop by to check out the furnace. BUURRRRRrr.

I just got my risers, waiting on minibars. A friend of mine "wussed" out on drilling holes for my top triple.

Great write up so far.
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Old 02-06-2009, 10:59 AM   #40
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Re: Suave's GSXR Swap Pictoral Guide.

Great write up thinking about doing this sv650s!!!
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