Suzuki SV650 Riders Forum banner

1 - 20 of 27 Posts

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #1
Years ago Zach (Fluke) & I started to talk about doing build project with his SV. We started to buy a few parts for the project like motosliders, rearsets, brake light pressure switch, R6 grips and throttle tube and a few other little pieces. Those parts then sat in a box for over 6 years. We always said okay lets start the project. Okay I'll bring you the bike in a couple weeks. Soon, we'll start soon. And so on...

Fast forward to November 2019. FINALLY! Zach and his wife made the trip up to Canada for a weekend visit and they brought "the fluke bike" with them.

If anyone is interested in following the build on Instagram it's @a_fluke_sv_build

Here are the pictures from the night the bike arrived.

51970


51971


51972


51973
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #2
Now a little history on this SV. It started as a blue 2001 SV650S. Im not sure if Zach was the original owner but I do know that he did the paint and put on the GSXR front end. This bike was at the National SV Rally in '08 and '09 and it did the trip out east to The Cabot Trail in 2010. Shortly after that it did a few track days, went down a couple times and has now been sitting for almost 10 years.

Lets take a closer look...

51974


51975


51976


51977


51978


51980


51981



Ummmmmmmmmm it's not looking good...
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #3 (Edited)
So obviously it's in rough shape but let's start to strip it down and see what we find.

51982


51983


51984


51985


51986


51987
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #4
So after tearing it down, assessing the condition, discussing future plans & end results, and a few puppers, the decision was made that this wasn't the bike to start with...atleast not all of it.
The time & money that would be spent to clean up all the corrosion, rusted hardware, and other issues we may find, not worth it. On top of that who knows how the motor is inside after sitting for almost 10 years with old oil and gas still sitting in it.
Having said that the GSXR front end was still good and we already have some key parts like an Ohlins rear shock, rearsets and now a complete donor bike.
So now the hunt begins for a good condition, low milage 1st Gen SV650.
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #5 (Edited)
After searching for a few weeks I found her. A black 2001 SV650S with 19,990 kms and 99% stock. The milage is about half of the original bike which is a nice bonus.

51989


51990


51991


51992


51993


51994


51995


51996


51997


SHE'S SO PRETTY!
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #6 (Edited)
The new bike also came with some great goodies. Not parts we will be using but good parts to sell.

51999


52000


52001


52002


52003
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #7 (Edited)
Okay so next step. Strip the GSXR front end from bike 1.

52004


52005


52006


Really Zach???

52007


52008


52009


52010


So that's basically it from bike 1. I'll keep it as a parts bike for now but that's about it.
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #8 (Edited)
Now before I get too far in to this project I should probably get some fancy NewAge cabinets. Wanted them for years and what a perfect time for a garage upgrade!!!

52011


52012


52013


Okay back to the build...
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #9 (Edited)
Okay time to strip bike 2. I did a time-lapse video of this and if I can figure out how to post it, I will add it later. Tear down took an hour and a half. For now here are some pics from the video.

52015


52016


52017


52018


52019


52020


52021


52022


52023
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #10
And the pile I was left with...

52024


52025


How she looked after the main tear down was complete. Side note: the back wheel is also not being used but for now helps hold the bike on the lift and keep it mobile.

52026


52027
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #11
Let's check out some of the fun bits...

Found a 1st gen Ohlins rear shock on Ebay. This shock has been discontinued by Ohlins so we grabbed it. It will be resprung and rebuilt before the final assembly.

52029


Next some SVR rearsets, some new OEM hardware, some stainless hardware, brake light pressure switch, spark plugs, front brake pads, motosliders and rear spools, motovation fork sliders, 2016 GSXR 600 front master cylinder (the old bike always just had the stock SV master), Progrip tank pad, 05 Yamaha R6 grips.

52030


52031


52033


52032


52028
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #12 (Edited)
The forks for the 06/07 600/750 forks are 48/50mm where the clipons attach. Woodcraft doesn't sell the 48/50 clamp with rise, or so I was told. So it was recommended that I get the stratight 50mm clamps and that would be fine. Well thats not the case. As soon as the 50mm showed up, I held them up to the forks and realized that only half the clamp was actually going to grab the fork tube. So I returned them.

Then after talking to Nate (Nudist on here) he suggested that I reach out to a shop called Motodemic. They have custom Woodcraft clipons made with the 48/50mm clamps for the Triumph 765 Street Triple. So after talking to Brad at Motodemic, I have the proper 48/50 Woodcraft clipons with 1.5" rise. Perfect!

Woodcraft clipons, BMC race air filter, Vortex V3 fuel cap, Woodcraft brake res bracket.

52034


52035



We have started to get closer to some of the final colours that we are going to use for this build so I was able to order the new Spiegler lines and Pazzo levers. I can't say enough good things about both these companies. Both parts were a custom order and were in the mail the same day I ordered them. Fantastic service yet again from both and that's why Pazzo levers and Spiegler lines are on all the builds I do. I added a small touch to the Pazzo levers as a suprise for Zach. Glad he likes them! 😁

Important note here: Remember when ordering levers for a front end swap that your brake and clutch lever may not be for the same bike. For this build I am using a '16 GSXR 600 brake lever and a '01 SV650 clutch lever.

52036


52037


Same important note for brake lines. In this case I am using a '16 GSXR 600 master with '07 GSXR 600 calipers and I am running clipons that are 1.5" taller than stock GSXR. This is all critical information for the banjo fittings used and the length of the lines. You want to get this stuff right the first time, since it's harder to try and return custom parts.

52038
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #13 (Edited)
Okay so I took a bunch of parts off. Now lets start to put some back on.

Rather than reusing the old bearing from bike 1, I ordered a new top steering stem bearing from TWF for the front end swap. Also I made an extreamly complicated, super cool, very expensive, awesome bearing tool that worked perfectly!!!

52041


52039


52040



Then I was able to install the GSXR front end.

52042


52043


52044


52045



Here are a couple before/after pictures of the original hardware vs. the new OEM/stainless hardware. These are the little details that cost $$$ but make a huge difference in the overall end result of the build.

52046


52047


52048
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #14
Also bolted up the new SVR rearsets and swapped out the old sliders for the new motosliders/rear spools. This was another point where have the parts bike was helpful. The old sliders that I took off bike 2 didn't mount in the same spot as the motosliders. When I took the old ones off I needed the proper OEM engine mount bolts so I pulled them off bike 1, and to my surpise they looked brand new (no rust). Win!

52049


52050


Here you can see the bolt I pulled off bike 1, right in front of the new motoslider.

52052


52051
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #15
We're almost up to date...

Next step was to install new Woodcraft clipons. This was a key component because I was then able to mount the control switches, new master cylinder, Spiegler lines, Pazzo levers, trim and install the R6 throttle tube and grips. I absolutely love how the new stuff looks! Great colour choices.

52053


52054


52055


52056


52057


52058



LOVE IT!
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #16
A couple days ago I put the Ohlins shock in. As mentioned it will be rebuilt before final assembly but it's in for now for fitting purposes.

52059


52060


I threw on the stock subframe from bike 1. There is a slight twist in it but I can hack it up and do some very loose temp fitting. Still not sure exactly what is happening with the tail section but it's in discussion. I am a pipe fitter by trade so I grabbed a couple pieces of pipe from work to use as mock up mufflers. Don't worry, I am NOT using these for the actual exhaust. It is strictly to the things out while we figure out the tail section and exhaust plans.

52061


52062
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #17
So now we're all caught up. This is how the bike sits right now.
Hopefully I get some shop time this weekend so stay tuned. 🔧🔩🏍
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #18 (Edited)
Weekend update:
I was able to make some good progress this weekend. I got about 6 hours of shop time on Sunday.
Since this will be a naked bike, one of the main goals is to keep the front end as clean as possible. I want the headlight tucked in nice and close to the forks. The decision was made to remove the fairing mount points off the frame to give more room for the headlight. First step was to remove the complete front end again so that there was no chance of damaging any of the new parts that were fitted. Once everything was out of the way I masked off the front of the frame. I used a portable band saw and the a grinder with a flap wheel to clean it up nicely.

52069


52070


52071


52072


Then while the triple clamps were off the bike it made sense to work on them as well. Since we are not running a steering damper, I cut off the mount on the lower triple clamp as well as cleaning up the casting mark that ran across the front.

52073


Part of cleaning up the front end is relocating the ignition. Cutting the ignition mounts off the top triple will allow the gauges to be ticked in nice and tight. This is why I used the 05 GSXR 1000 top triple because of the way the ignition comes off the front and isn't set into the body of the clamp.

52074


Then it was time to put the front end back on.

52075


52076
 

·
Premium Member
Joined
·
4,091 Posts
Discussion Starter #19 (Edited)
While I had all the tools out, I decided to work on the ignition brackets. First I had to decide where the mounts would attach and then start to design and fit the brackets. Cut, file, grind, test, drill, cut, grind, test, file...! I am happy with how it turned out. The brackets and the ignition will be painted black later on.

Also Shop Tip: If you don't have proper soft jaws for your vice, tape and popsicle sticks is a cheap and effective solouition.

52077


52078


52079


52080


52081



While the garage is warm, lets keep going.

I previously took the rear brake setup off the bike because we weren't sure of how we were going to mount it. We have deiced to just use the stock caliper and location. I took the stock assembly apart and remounted the caliper, support arm and rear master cylinder. Then I was able to fit the new Spiegler brake line. I have to swap up the banjo bolts as the ones I got were the wrong thread but I haven't bled the brakes yet so no big deal.

52082


52083
 

·
Premium Member
Joined
·
122 Posts
Nice Work. I also bought a used Ohlins for a Gen 1. By way of this awesome forum I was able to get some pretty expert set-up advice from Rich Demond on this thread;


Bottom line is the proper length for this adjustable shock is 152mm. This will raise the back of the motorcycle by quite a bit, just something to be aware of if you're not already.

I can't wait to see your finished product!
 
1 - 20 of 27 Posts
Top