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Discussion Starter #41
Working lower triple clamp.
Cleaned out with steel wool. Chased threads and bolts. Waiting for bearing set. Suzuki make head bearing set that includes two bearings and dust seals, whole kit for bout 70 bucks delivered. Better deal than buying items separately. Waiting for delivery.
Lower bearing race looks pita to remove. Not sure if my home compressor will run my I&R air chisel, if so job will be quick....
 

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Discussion Starter #42 (Edited)

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Discussion Starter #43 (Edited)
Evotech tail job:

Evotech instructions are here:

http://images.cloudcommercepro.com/00000379/pdf/004201SuzukiSVTailTidyInstructions.PDF

Selected evotech because I wanted to retain tag light and oem turn signals. Evotech piece is kind of pricy at 100 bucks.

Just finished installation, not impressed at all. Oem turn signal Reinforcement bar didn't fit, self tapping hardware was not there for the upper plate. Instruction were sketchy. Mounting hardware for an merican tag are joke. There was no hooks to retain relay block. In short shyte.
Looks good though.:evil6:

http://www.sv-portal.com/forums/album.php?albumid=1282

At the end I attached relay block to the seat latch bracket. Secured well, finally happy about its location
 

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Discussion Starter #44 (Edited)
I supposed to get last parts yesterday but I didn't. Boomer. Went fishing, cut nothing. Boomer. Better day today hopefully, test drove around nignborhood for a first time with new front end. Still faring is off and ignition switch not connected but bike runs fine on new forks.

Last parts are two cooling hoses that connect to thermostat housing and cylinders. I will dig to them and replace fuel filter with new one plus relocate ignition switch to left side. All one job I won't start unless I have all parts on hand.

http://www.sv-portal.com/forums/album.php?albumid=1290
 

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Discussion Starter #45 (Edited)
Finally our everything together and drove phase II bike yesterday.
Came out really nice.

http://www.sv-portal.com/forums/album.php?albumid=1266&pictureid=12634

More pics in swap album

http://www.sv-portal.com/forums/album.php?albumid=1266

I spent lots of time trying to place ignition switch and retain its full functionality. Finally I have workable design, just bit fabrication left to do.

First impressions: bike is quicker to turn, yet stable. USD Kayabas make better job over rough surfaces. TLS bars feel like SV stockers.
 

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Discussion Starter #46 (Edited)
Those who follow from the beginning know that I made conversion to external Toyota pickup filter. Filters I get are inexpensive and quick connecting so replacements are snap.
http://www.sv-portal.com/forums/album.php?albumid=1298&pictureid=12618

With tank removed and all work associated with swap I took opportunity to replace fuel filter with new one. That is 3 rd filter I have changed since I cleaned the tank. All to the tune of 24 dollars delivered. Try to price that for factory junk design.
To have more room I am removing filter bracket attached to the filter, just keeping filter body
http://www.sv-portal.com/forums/album.php?albumid=1298&pictureid=12610
While at it I noticed connection to the fuel hose connector at the TB end developed a leak. IIRC manual suggests replacing fuel hose after 5 years in service, mine was overdue. Note that date of manufacturing is stamped into connector bodied.

http://www.sv-portal.com/forums/album.php?albumid=1298&pictureid=12626
 
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