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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 02-09-2009, 06:49 PM   #41
SuaveNotion
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Re: Suave's GSXR Swap Pictoral Guide.

Well I got my hall effect sensor the other day but due to a lack of a camera I was unable to get pics posted until now. So i'll put up the pictures and I'm sure that you can use your imagination as to what it looked like before i put it on...


Also the bracket that I made there is really a test one made from sheet aluminum until I can have one made out of a thicker material. It's about 7x3.5 inches.

And here it is sitting where it would be if the fender were on...


And the old one...


Since i soldered it before I was able to put up a wiring diagram I'll just say what the wires are...
SV SENSOR HALL EFFECT

12V Orange/Red → Black/Red

6V Pink → Black/White

Signal Black/White → Black

The SoCalSV writeup that I orinally used for this post is WRONG. The pink wire is the 6v and the Black/White wire from the SV harness is ground/signal. BE AWARE! It is very useful to check the voltage with a volt meter just to double check. I got burned by this the first time and had some trouble before I got it working "properly".

I'm still waiting on the Neodymium magnets to come so yet again my project is stilted by USPS...

Last edited by SuaveNotion; 03-06-2009 at 09:28 PM.
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Old 02-14-2009, 08:08 PM   #42
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Re: Suave's GSXR Swap Pictoral Guide.

Well finally my magnets are here and of course they aren't the right size... Apparently the GSXR has a diminishing diameter in the holes of the rotor for what I guess is added ridgity.

So it required me to go against the advisory on the magnet site and I had to cut them to size. I bought 3/8" X 3/8" and the right ones would have been 3/8" X 1/4". Oh well..
They fit anyway so who really cares at this point.



So this is kind of what they look like. Thankfully the mutilated side goes on the inside.

After this you can mount the sensor and the fender. Since the SRAD forks are wider unless you get some sort of custom fender the GSXR fender will not fit on the bike. So I decided to go with the BUSA fender..Not my first choice but whatever.
Here it is mostly put together:


Then you go ahead and get yourself some headlight brackets. There are several kinds but I decided to go with aztec8 parts since that's what a lot of people do and they're not that expensive. I used 4: 2 48mm's and 2 54mm's. Of course they dont make 53 but the lower 54's are really only there to keep the headlight steady so it worked out ok.

Now since the forks are wider, the aztec 8 parts will need to be cut. I cut one side of the 2 piece clamp so that the headlight bracket itself will fit within the forks. I didn't really measure as you have some leeway since the headlight bracket is rubber mounted and bends a little. However, you have to be VERY careful not to cut too deep otherwise you will compromise the ridigity of the pieces.

I don't have a pic of the cut pieces because I put them on before I got my hands on another camera but I'm sure you can use your imagination.

Here's the headlight on the bracket after everything is said and done.
Note how the inner side of the aztec8 piece is smaller than the outer one:





And the bike how it is now:


All that is left is a set of brake lines from cyclebrakes and then that will be it.
What a **** ton of work...
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Old 02-18-2009, 11:14 AM   #43
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Re: Suave's GSXR Swap Pictoral Guide.

nice pictorial! I wish I had the patience to have taken a bunch of photos of the "during" the swap... Filing the neck of the frame was no big deal, just found an old round file and went to town for a few minutes... I laughed at the "light tapping" to get the race out. I had to pound pretty dang hard! lol

And, hopefully this won't spawn a ton of chatter (I hate getting huge, off-topic posts), but I though that the 06-07 forks had different diameter upper and lower fork tubes or it had some strange tapered upper triple clamp? But, I guess you figured it out, and it looks great. You'll love it, i love mine!!

What part of WI are you in?? I'm in western Chicago burbs... Maybe I'll see you on an ABC ride this spring!

Props for the Grand Candy Blue too, I love that color!! Although, I haven't seen it in person, but that blue AGV S-4 helmet looks the bee's knees (if I ever get a custom paint job)!!
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Old 02-18-2009, 11:46 AM   #44
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Re: Suave's GSXR Swap Pictoral Guide.

Yeah I actually lucked out on that helmet. My dad bought an R1 a few years ago (which i evidently crashed...) that came with that helmet. But my dad lives in Florida now and is rather anti-helmet so gave it to me. Good thing it happened to be blue since I bought the bike after i had the helmet haha.

The forks do change diameter a few times from top to bottom but where the triples clamp they are the same, thankfully. I actually had to buy a couple of punches before I bought the BIG ONE which turned out to be about 14inches long and after that and about 4 hammer taps it popped right out. The bigger the tool, the easier the job apparently.
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Old 02-19-2009, 03:57 PM   #45
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Re: Suave's GSXR Swap Pictoral Guide.

Also curious about where in WI you might be hiding - I'm in the Milwaukee area (and thinking about doing something similar to my sv next winter hehe)
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Old 02-20-2009, 02:02 AM   #46
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Re: Suave's GSXR Swap Pictoral Guide.

This is the story on the fork/triple relationship Apollo ......

Quote:
Originally Posted by Apollo1777 View Post
.... I though that the 06-07 forks had different diameter upper and lower fork tubes or it had some strange tapered upper triple clamp? .....
Quote:
Originally Posted by D'Ecosse View Post
....
You will also need shims between those fork legs & lower triple clamp - the SRAD is for 54mm legs, those Showa 06+ forks are 53mm. So you will need some 0.5mm (~20thou) shim material to make a sleeve. ...
Quote:
Originally Posted by SuaveNotion View Post
...
Now if you have a set of 53mm forks and a set of 54mm lower triples like i did, it will be necessary to either purchase or fabricate a 1mm spacer to accomodate the gap. I simply purchased a set of shims from convertibars for 20-something dollars, but making your own will definitely be cheaper.

...
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Old 02-25-2009, 01:59 PM   #47
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Re: Suave's GSXR Swap Pictoral Guide.

Quote:
Originally Posted by SuaveNotion View Post
Yeah I actually lucked out on that helmet. My dad bought an R1 a few years ago (which i evidently crashed...) that came with that helmet. But my dad lives in Florida now and is rather anti-helmet so gave it to me. Good thing it happened to be blue since I bought the bike after i had the helmet haha.

The forks do change diameter a few times from top to bottom but where the triples clamp they are the same, thankfully. I actually had to buy a couple of punches before I bought the BIG ONE which turned out to be about 14inches long and after that and about 4 hammer taps it popped right out. The bigger the tool, the easier the job apparently.
That's funny. I had a blue/white jacket and blue gloves for my first gear, and I had a black/gold 89 Yamaha Radian for my 1st bike... Then I got my SV to match my gear too!!

Any more pics?
Here is a current picture of my poor baby :
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Old 02-25-2009, 07:17 PM   #48
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Re: Suave's GSXR Swap Pictoral Guide.

Its lookin real good. In fact it looks just like mine haha. Why does your shifter look so low? I also like the silver engine you got under there. Definitely rally worthy!
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Old 02-25-2009, 10:29 PM   #49
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Re: Suave's GSXR Swap Pictoral Guide.

Well...the very last part is due for arrival on friday. It's the reservoir bracket from cyclewerks. I will have a picture of the completed bike outside when it warms up a bit so that could be anywhere from now until April...

The mod list goes as follows:

06/07 GSXR 600 forks
08 GSXR 1000 front wheel
97 SRAD upper and lower triples
Convertibars fork shims
cyclewerks reservoir bracket
07 GSXR 600 rotors and master cylinder
Galfer SS brake lines
TWF top bearing kit
Aztec8 headlight brackets.
Custom made axle and wheel shims
07 GSXR 1000 front axle
random year hayabusa fender
Hall effect speedo sensor with "custom" bracket
Lots of finesse...

Thanks to everyone who posted on here, especially those who brought to my attention the fact that the forks are wider apart and required shimming. I hope this is helpful to anyone else who cares to do a GSXR swap to a GenI SV.
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Old 02-26-2009, 12:15 AM   #50
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Re: Suave's GSXR Swap Pictoral Guide.

the shift rod is disconnected. I've removed the old shift cable with the intention of replacing it with that MotionPro one...

I thought the silver engine was standard? (I just looked above and I see yours is black. Hrm.)
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