[Sanyarcosean]

I've always wanted an SV650, they seem like the swiss army knife of the motorcycle world. I've not bought one up until now because I'm cheap and didn't want to pay the money that 2nd gen bikes were bringing. I have been keeping a close eye on FB Marketplace and Craigslist looking for a cheap project but money and availability never seems to align.

Then about a month ago things fell into place for me to acquire a pretty poor example of a 2nd gen SV650. It was in pieces, had a title issue and the last 2 owners failed to get it to run on anything other than starting fluid. With that knowledge in had I shrewdly negotiated a price and hauled my new junk home.

Here it is in all of its glory as advertised.

 

[mad8vskillz]

nice. i like the vinwiki shrewd negotiator saying heh

 

[Sanyarcosean]

Lets get her in the shop and cleaned up a bit. It had sat for YEARS and was pretty dirty.

That's better, now lets evaluate what I got and form a plan. The main issue seems to be that the fuel pump isn't powering up. Its also had its main engine harness butchered. This could be the root of the problems. My plan as of now is to clean the throttle bodies and put injectors in them ( the P.O. threw the old set out). Check the fuel pump/filter assembly, and then put the bike back together. Once its back together, try to get it to fire and go from there.

I didn't think to take pics, but you all know what these things look like. I put everything back together and just like those before me, I couldn't get the fuel pump to power up, but it would fire on starter fluid. Putting the bike in dealer mode showed a C41 fuel pump control issue. At that point it was time to get some parts before I could move forward. I decided to pick up a Fuel pump relay, bank angle sensor, relay from the fuse box and main wire harness. I also wanted to get a tank as mine was horrid inside.

It was at this point that I found @mad8vskillz on youtube. He had just done a video on a bike with a tank he was going to scrap.. Hey, that tank is better than mine... A quick message and we set a time to pick up the parts I needed ( plus some ) As you all know, he's a stand up guy! I ended up bringing home a nice harness with all electricals on it, (2) tanks and hardware, a couple of fuel caps, a scrap fuel pump for parts, shifter lever, rear brakes, steering dampers and a really ratty set of lower fairings. I'm sure I am forgetting something. This however gave me the parts to try again to make it run.

Yesterday was the day. I swapped fuel pump relays, hooked up a fuel pump an put it in dealer mode again. No fuel pump power and still getting the same C41. I followed one of the the relay trouble shooting posts and it looks like it may be the ECU not triggering the pump. I've got a spare on the way from Mad8v, but I still have not ruled out a harness issue. Next I jumpered power to the fuel pump and to my surprise the nasty little bugger came to life. So I install the pump in my frankentank. This thing is ghetto cool, it had a section cut out of it to fix a hole and a patch was tig welded in. It isn't pretty but its clean. I hooked up all the fuel system, threw 2 gallons of fuel in it and put that jumper back in for the fuel pump. Ignition on pump on check..... A few squirts of starter fluid down her throat and she came to life. It took a little work to get fuel everywhere it needed to be, but it eventually ran and settled into an idle.

So that's where I am. Now that I know its going to run, its time to collect parts and work some Vermont Magic to get a title. Ill update as I make more progress

 

[Sanyarcosean]

nice. i like the vinwiki shrewd negotiator saying heh

Ed is one of my heros! I had originally called this bike "The world worst example of a 2nd gen SV650" on facebook. Even tagged Ed. Then I found your channel and realized in comparison to some of the stuff you've drug home this bike isn't that bad.

 

[thedrewski86]

Excellent work Sanyarcosean! Your process of diagnosis is a testament to the craft and to the wealth of info and help available here. Great to hear it run!

 

[Geo Smith]

Welcome to SVR Sanyarcosean. Nice work thus far. I'm looking forward to following your progress.

 

[Kenneth]

Nice work, I like the way you roll.

 

[Sanyarcosean]

Quick update, the new to me ECU showed up today from @mad8vskillz. I swapped it into the bike and the fuel pump works like it should now! So bad ECU for the win!

 

[shredG]

Well done, welcome and looks like a solid project you have there

Great progress already

Props! ;-)
look fwd to the next installment ;-)

 

[Sanyarcosean]

Just a quick build update!
I've been in parts collection mode over the holidays, that and shop cleanup so I can start hitting this bike hard. Still a little work to do in the shop, but at least I've got it on the build table now!

I've also been selling off my other projects to gain space and be more focused. I sold my last project yesterday and then immediately found this on market place.
2006 with 50,000 miles on the clock. Of those its last couple hundred feet were spent on its side sliding down the road. It still runs and has a clean title. At quick glance it doesn't look all that hateful. I put a deposit on it yesterday and am all set to pick her up tomorrow. Once its home Ill do a good evaluation on it and see where we are.

If the bike is straight, it will become the primary build and I'll start a new thread for it. If that is the case, one of three things will happen with the original bike.
Option 1, It gives parts to build the new bike
Option 2, The original bike becomes a track day build ( Something I kinda wanted to do at some point anyway)
Option 3, I continue the build on the original bike after I finish the new one and it gets flipped.

I like options.

 

[thedrewski86]

It's good to have options
Killer shop, looks like you will have a good time with whatever build you choose!

 

[Sanyarcosean]

So here is the latest update on this one... I'm building it with my son as his first bike now while I also work on the '06 for me. As of now, we've added a good used tank, rebuilt the forks/steering head as well as front brakes. Also has a fresh front tire. Next up, we start looking at the rear of the bike. It shouldn't take much more now!

 

[Geo Smith]

Nice! Looking back at your post #10 pic, did you build the build stand?

 

[Sanyarcosean]

Nice! Looking back at your post #10 pic, did you build the build stand?

Thank you! Yep, its based on a WW2 military Harley Service Stand. The Plans are here if anyone is interested WW2 Harley Service Stand

 

[Geo Smith]

Very cool! Thanks for the link.