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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 05-30-2019, 07:26 PM   #1
Johnpewpew
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motor rebuild

hey guys,
so at the last round of the LRRS going into turn 1 me and the bike had i disagreement. lost the front end and went for a slide. the bike went down on the left side and slammed the shift shaft. well when i went to go fix the shift shaft i found that it had broken the case internally. so now im looking at a full motor tear down to fix it. luckily i have a spare case. now iv never done this before. i have acquired a factory service manual and i am very mechanically inclined, my day job is industrial maintenance tech. so as with rebuilding anything there are tricks, tips, do's , and don't. Any advice would be helpful. now some history on the motor. its a race motor its been all its life. at some point it had a 1mm over boar done to it. with the 1mm over boar is there anything i would need to do out of the scope of the service manual? and while the motor is open what should be replaced/upgraded?

thanks for you time guys i will try can keep this updated as i go.
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Old 05-30-2019, 07:28 PM   #2
Johnpewpew
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Re: motor rebuild





new case
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Old 06-01-2019, 08:21 AM   #3
RecoilRob
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Re: motor rebuild

Nice!! That should be a fairly straight forward project. While the heads are off I'd go through them just to make sure they're tip top and install fresh seals. Will be interesting to follow your rebuild.
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Old 06-07-2019, 06:05 AM   #4
Johnpewpew
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So it started.
Got the motor out and on the bench yesterday. The tear down will start this weekend.
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Old 06-07-2019, 09:21 AM   #5
Junkie
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Re: motor rebuild

Piston material may be different so ideal ptw may be different, but that's just a guess. Procedure for the rebuild won't be any different.

I'd want to make sure squish is set properly while you have it apart.

Were you running a flipped shift knuckle for reverse shift pattern? If so, and if you want to continue doing so, I'd recommend at a minimum drilling some holes in the knuckle to make it break easier vs breaking the case.

And I assume you know that the cases are machined as a matched set, as with (for example) main caps, rod caps, etc. I'm hoping you have both sides.
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Old 06-07-2019, 01:52 PM   #6
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Re: motor rebuild

I'm really hoping that when I rode my bike into a traffic island the other weekend at low speed and caused me to low side that I didnt damage my shift shaft, the bike didnt want to go into gear properly, when I put it into first it was very slightly engaging and with the clutch lever all the way out was only just harder to push the bike along than if it had been in neutral. I really hope it's something simple like a clutch cable thing.

My bike's in the shop and they took all week to get back to me via phone while I was busy at work and I asked if they could send me an email with the information about repairing the bike and that was at 3pm yesterday, now its Saturday morning and still no email, going to have to go in and see them today.
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