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Discussion Starter #1
2 Weeks ago, I was in a minor accident while taking evasive action to avoid becoming part of an SUV's driver side front door.

She decided to gun it out of her driveway to make a left turn across two lanes, directly in front of me. Thankfully, I was able to avoid a full colliosion, but as I got around the front of her car, she clipped my tail and the bike highsided me.

"I didn't see him, officer."

Yes, because I watched as you pulled out looking straight ahead, genius. That's how you kill people.

Thankfully, the bike got the worst of the damage.

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First some mod history on the SV's current setup:

2000 SV650 Naked
• Custom blue retro metal-fleck paint
• Custom decals (under clearcoat)
• Fender delete
• Jetted
• K&N filter
• Micron Race Oval high-mount system
• Spiegler braided brake lines
• RaceTech rebuilt forks
• Suburban Machinery Type 2 Bars (their first generation... 9 years old!)
• Vortex Sprocket | RK Chain
• CRG Bar End Mirrors
• CBR600 replacement R/R


Some shots of the damage:

Hmmm.... i don't remember owning an undertail exhaust setup...



CRG Mirror housing is tough as nails. Scratched badly though.







Here's the marks on the street from the slide. Awesome. :unamused:



Here she is, getting the royal treatment.





So, what to do when you have a motorcycle that needs some disassembly and significant part replacement, but live in a garden apartment without access to a garage?

Setup a shop in your dining room, of course!



Of course, I can't let the neighbors or the super see... so I have sophisticated stealth technology employed.




Time to start disasembling and assesing the damage.

Hmm... this doesn't look right.



Man, this thing is dirty!





After some cleaning...





So, with the tank, tail and front fender off, I can get those over to the body shop for paint prep.

Here's what I've ordered so far, based on what was damaged:

• CRG Folding Mirror (and new folding stem for the existing left side mirror)
• CRG Gold Shorty levers
• Replacement Front & Rear Master Cylinders
• Replacement throttle assembly, toggles and throttle cables
• SVRP Silver Rear Sets (Blair)
• Banjo bolt pressure switch
• M4 Carbon Canister only (Blair) - going to make it work with the existing Micron plumbing
• Driven D3 Grips (gold) and Bar Ends (black)
• Suburban Machinery Type 2 Bars
• Targa Exhaust Shield (my old chrome one looks like poop after 9 years)
 

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Discussion Starter #2
Paint Scheme

Still in need of:

• Replacement parts for my mangled headlight :( Hard to find... HELP!
• Motosliders Frame Sliders (I hate how sliders look, but it's time...)
• PAINT JOB!



Here's the plan for paint:

British Racing Green, or something similar with an offset Gold racing stripe
(similar racing stripe style as the Monster S2R style from a few years back)

How hot is this little Ford Escort?




I'm almost certain that I am going to to try the matte finish clearcoat to instead of a high gloss... just something different, and I think it will look super slick with the gold stripe!

More to come...
 

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Discussion Starter #4
Some parts started to show up in the mail:

Left and Right toggles
Very clean throttle cables
New Rear Master
Slick Targa Exhaust Shield




With this, I can get moving on the handlebars and re-attach the whole throttle assembly. I'll just need to install the D3 grips, bar ends and mirrors, and levers (when they arrive) and the handlebars will be done.

I was able to track down a headlight, which was the last item I needed to find!
 

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Discussion Starter #5
Got the throttle assembly back together, cables attached and everything working well.
Used Suburban Machinery's turn signal brackets to relocate the signals to the lower triple tree. Not sure about how it looks yet, but I'm giving it a try.

Need to get those grips so I can get the toggle assemblies into their final positions and tighten everything down.

Drained the fuel tank as well last night... just waiting for all the gas to fully evaporate, then I can send all the bodywork to a shop.



Here's the Targa heat shield.

 

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Discussion Starter #7
More Progress

Some more parts have arrived, and some more parts have been mounted.

Dry fitted the rearsets. Trying to find a good position, but it's always a little tough on a swingarm stand, because the bike is on a forward angle. None the less, the ride position will be quite different than it was stock. Once I am happy with their location, I will loctite everything per Blair's suggestion. They're sweet.

Also mounted the rear brake cylinder as well as the front master, reconnected all the brake lines and made sure everything fit snuggly.

I needed to shorten the feeder hose from the rear reservoir to the rear cylinder by about an inch, as the SVRP rearset holds it a bit higher than the stock position.

Since I was at this point, I decided I'd attempt to fill and bleed the brakes. Luckily everything went flawlessly. I used the gravity method with a little piece of tube, an empty beer bottle and some patience. She's ready for stoppies again. :D

I've been chomping at the bit for my grips and bar ends! I want to get the handlebars/controls into their final positions and get it all tightened down! They'll be here wednesday.

I tracked down a VERY clean Gen1 Master Cylinder and nearly perfect Gen1 headlight assembly! I have everything replaced!




Dang! CRG makes the sexiest bits!


 

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Discussion Starter #9
Finally received the Driven D3s and bar ends. So happy to get the handlebars fully secured, all assemblies tightened down and mirrors in place.

Also found a reputable custom bike shop that's handling the paint job. Dropped off the parts today!

 

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Discussion Starter #12


BACK ON THE ROAD!


Finally got the parts back from the shop, and they came out AMAZING!

I'll let the photos speak for themselves.

I'm done for the summer... but there's still much to do.

Engine is still very messy, especially along the bottom of the bike.
Need new front tire
Need to either paint or replace frame covers and tail piece behind rear seat
Contemplate GSXR front end....

Enjoy!





 

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Discussion Starter #15
The bike is snuggled in and cozy back in my living room for the harsh New England winter.
Front wheel coming off shortly for a new sneaker, and the detailing/cleaning shall commence. I want to go over the whole bike and try to fix, replace the little things that are still wrong/broken/damaged, etc. Minor stuff.

I'll update soon with photos. Enjoy the cold! Snowboarding time...
R
 

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Discussion Starter #16
Finally got a little more done... rattle-can magic on those tired frame covers:

Before (yikes!)


After!






I owe everyone a nice photo with them mounted, but this will do for now...



It's a small change, but somehow makes the bike complete... :icon_biggrin:
 

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Discussion Starter #17
It's hard to believe that it's been SEVEN YEARS since I've updated this thread.

One reason is that there haven't been many additional mods to the bike since I did the full overhaul back in 2010, but I have done a few things... and most importantly, I've done a lot of overdue maintenance on my own that I hope will inspire other newbs to do this kind of work themselves.

Here's what I've done this season:

CARB REBUILD

Warning - PIC HEAVY

Let's just say this was years overdue... years.

The bike hasn't idled well since the "oughts," but otherwise gave me no real hassle. Then, toward the end of last season, I started getting chronic backfiring on decel. Pretty sure sign of pilot jet clog... So I knew it was time.

First, I picked up a pair of K&L Carburetor Repair Kits 18-5068. I grabbed these on Amazon for fastest delivery.

While awaiting the new rubber parts, it was time to pull the carb assembly. Boy is it shamefully filthy:



While removing from the bike, I stripped one of the screws holding the choke cable to the carb body... nothing a little dremel mod can't solve ;D



Now for the teardown... this could have gone in so many (potentially bad) directions... but after all was said and done, I was pleasantly surprised by the condition inside the carbs.

Not terrible (but not good, of course):



Here, you can see that the seals were beyond their expiration date... but they still did a decent job for never being replaced in 18 years:



You can see all the "frosty" deposits on the jets quite clearly...





Now it was time for cleanup. Doesn't this look much better?! (note my note-to-self re: Air/Fuel screw):




And now with everything ready to be reassembled, all new gaskets, O-rings and float valves at the ready:



Much nicer!




While I was at it, I gave the rest of the engine / interior a little overdue cleanup:



Carbs back in place. Let's hope that effort solved my backfiring and idle issues:



Next on the list was a bunch of other general maintenance that was long overdue:
  • Oil and Filter Change
  • Coolant flush and replacement (removed Rad completely and flushed)
  • Battery Upgrade (LiPo - amazing!)
  • Fresh Spark Plugs
  • Cleaned and re-oiled K&N Filter
  • Chain / drive train degrease and lube (man was it nasty)
  • Installed Horn upgrade: FIAMM 72112 Freeway Blaster LOW (what a difference)
The chain cleanup was worth documenting visually. Look at this SHAME:





My new favorite thing in the world - Kerosene in a spray bottle. BOOM:



I picked up a "Grease Ninja" for a more controlled and clean lube job. It's brilliant... gets the lube where it should go, and prevents it from getting where it shouldn't. This should keep the goo at bay.


AND HERE SHE IS - after all that TLC:



Boy oh boy, I should have done the Carb rebuild years ago.

The bike starts on a dime, idles perfectly and at the spec rev count, and runs like a dream. Honestly, it hasn't run this well since the day I jetted it back in 2002.
 

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Discussion Starter #18
With all the powertrain maintenance complete, there were a few additional critical updates that were needed.

First and foremost was a new front sneaker. I always pull the wheels from the bike myself when doing tire changes. You'll save yourself quite a few bucks that way.

I still have not purchased a steering head / front stand, so I had to improvise for the front:



It's more sturdy and secure than it looks, I promise!

While the wheel was off and getting the tire mounted at my local shop, I went ahead and put new brake pads on - EBC HH are my go-to:



You'll want part numbers FA229HH and FA231HH, if interested.

While I was at it, I cleaned the calipers as best as possible while still connected to the brake lines. They need a rebuild, and are on the list for this winter's projects. One of the dust seals is starting to budge out on one piston. Fun!

Another overdue maintenance item, which has improved feel and control in leaps and bounds: cable lubing. With one of those cheap cable lube clamps, I was able to lube everything while still in place...just removed the cables from top side and sprayed away:



The last thing I did was snake a long Apple Lightning Cable from my battery tender pigtail (in my trunk) to the front of the bike, and tossed on a simple RAM phone mount. The cable sneaks out between the front tank mounts. Very clean, and can be tucked out of the way when not in use.

It's a great upgrade for route planning, which you can see below (sans phone):



OK - enough about maintenance.... here's some gratuitous road photos!

Harriman State Park





Bear Mountain



Hawks Nest





As always, I appreciate any and all feedback (be it praise or critique) in my feedback thread.
 

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Discussion Starter #19
2019 Winter Maintenance Update

Keeping with the momentum of my other maintenance duties, I decided it was time to try giving the front calipers a rebuild.

I was a little intimidated, but after a good amount of research and conversations with friends that have done it many times, I gave it a go... and it wasn't bad at all!

First, I picked up a pair of Caliper Seal Kits from Brake Crafters:



It seems like a solid kit, which includes pressure + dust seals, boots, bleed nipple, crush washers and their special rubber grease.

Next, it was time to pull the calipers, and do my best to remove the pistons.

After some careful work (don't touch the outside of the pistons with any kind of tool!) and VERY careful use of pressurized air (wrap the caliper in a shop rag before shooting air into the caliper to remove stuck pistons!), I was able to move forward:




Once again, I was pleasantly surprised at how clean the insides of these were, considering their age! These have never been apart since the bike came off the factory floor.

Next, cleanup-time. I did a decent job, but didn't go too crazy. All of the external areas around the brake pads will just get filthy after the first few hundred miles, so I wasn't overly meticulous about the outsides.

The insides, however, were now spotless (here's a side by side of clean vs. dirty):



Assembly was very easy... drop in the pressure seals, dust seals, slip in the pistons, add new nipple, add boots, grease pins and put it all back together.

Next, use new crush washers on the banjos and begin the process of bleeding. I opted to flush the brake lines through with new fluid, basically emptying the reservoir a solid 3x to ensure the lines were flushed.

Once I started bleeding, I needed to release trapped air bubbles from each of the banjos, top to bottom... but after that, I had good feel in the lever, and was ready to go.

She's still put-by for the winter, so I haven't given her a proper test ride with everything complete. Once it's warm, I'll stay close to home and get things up to temp to ensure everything is working correctly, and there's no leaks at the seals in the caliper (scary!).

That's all for now....:eek:ccasion14:
 
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