Suzuki SV650 Riders Forum banner
Cancel

Sanyarcosean's 2003 SV650 Build

2381 Views 31 Replies 8 Participants Last post by  Sanyarcosean, 
S
4
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.
Automotive tire Automotive fuel system Motor vehicle Hood Automotive design

Tire Wheel Automotive tire Window Tread

Automotive lighting Automotive design Bumper Automotive tire Bicycle part
Automotive tire Motor vehicle Automotive design Automotive lighting Personal protective equipment
See less See more
Reply
Save
Like
  • Like
Reactions: 3
21 - 32 of 32 Posts
S
5
Today, I got the rear tire mounted and balanced and finished installing the new chain/sprockets. I also replaced the brake side rear set as it was hammered. also rebuilt the rear brakes and hung the tail. Still have to paint the grab bar. Moving right along...
Tire Wheel Vehicle Automotive tire Motor vehicle

Machine tool Engineering Gas Wood Machine

Wheel Tire Automotive tire Automotive lighting Fuel tank

Tire Wheel Automotive tire Motor vehicle Automotive lighting

Motor vehicle Tire Automotive tire Automotive design Automotive exterior
See less See more
Reply
Save
Like
S
2
Grab bar painted.
Tire Wheel Automotive tire Automotive lighting Vehicle

Tire Wheel Motor vehicle Automotive tire Blue
See less See more
Reply
Save
Like
  • Like
Reactions: 1
Geo Smith
Damn bud, that actually looks much better than I would have expected. Most here are trying to remove the handle and cover the holes to look racy. You painted it white, making it look like an ass spoiler. Looks cool, and you still get the functionality of a grab handle. Nice work.
Reply
Save
Like
thedrewski86
Geo Smith said:
Damn bud, that actually looks much better than I would have expected. Most here are trying to remove the handle and cover the holes to look racy. You painted it white, making it look like an ass spoiler. Looks cool, and you still get the functionality of a grab handle. Nice work.
Click to expand...
A good grab handle is a thing of the past, like center stands. I love that my SV has one and I use the center stand on my 250 all the time.
It's the little things...
Reply
Save
Like
  • Like
Reactions: 1
Flash Yellow
thedrewski86 said:
A good grab handle is a thing of the past, like center stands. I love that my SV has one and I use the center stand on my 250 all the time.
It's the little things...
Click to expand...
I like the handle grab bar as well. It is awesome.
On my Gen 2 unfortunately I can not run it because I have a SW-Motech luggage rack, which I think looks pretty cool too.
But, nothing for a passenger to grab onto.
Reply
Save
Like
Flash Yellow
Sanyarcosean said:
Grab bar painted. View attachment 66242
View attachment 66241
Click to expand...
I really like the paint job on this handle bar. Can you tell us how you did it? I have not painted any SV parts before but I would like to learn and there are a good amount of things I would like to paint.

Great work! Your son is going to love it. The ladies are going to appreciate the grab bar.
Reply
Save
Like
S
Flash Yellow said:
I really like the paint job on this handle bar. Can you tell us how you did it? I have not painted any SV parts before but I would like to learn and there are a good amount of things I would like to paint.

Great work! Your son is going to love it. The ladies are going to appreciate the grab bar.
Click to expand...
To paint the Grab Bar:

The original finish was good, so I just scuffed it very lightly with fine steel wool, then cleaned it really well with acetone.

Fortunately, the white on the fairings was a pretty close match to Rustoleum 2x gloss white spray paint. I gave it 2 good coats of that. No primer needed. I let it dry for about 30 minutes then top coated it with SprayMax 2K high gloss clear spray. Its expensive, but it's a 2 part paint/hardener and will survive fuel spills and most other fluids.

I used the same process on the wheels and will be painting the tank in the next day or two.
Reply
Save
Like
  • Like
  • Helpful
Reactions: 2
S
4
More progress today, including some customs graphics.. I have the Suzuki printed for the tank. Once it’s on I can clear the tank and start final assembly!

See less See more
Reply
Save
Like
Flash Yellow
Is that sticker referring to your sons mom?
Reply
Save
Like
S
Flash Yellow said:
Is that sticker referring to your sons mom?
Click to expand...
Nah… she significantly louder than his bike. ;-)
Reply
Save
Like
  • Like
Reactions: 1
Flash Yellow
Maybe go full exhaust system, it may be louder?

I have only run slip on exhaust on mine. Been reading about these header bolts that break off during removal so, I will have to learn how to remove the front header properly.
In order to run that sticker mod and not be lying.
Reply
Save
Like
  • Like
Reactions: 1
S
Tank graphics finished and clear coated… on to final assembly!
See less See more
Reply
Save
Like
  • Like
  • Love
Reactions: 3
21 - 32 of 32 Posts
Suzuki SV650 Riders Forum
A forum community dedicated to Suzuki SV650 owners and enthusiasts. Come join the discussion about performance, modifications, racing, troubleshooting, maintenance, and more!
Full Forum Listing
Explore Our Forums
Motorcycle Talk Off Topic Riders Lounge SV Modifications and General Maintenance SV650 Gen2 (03-15) Tech SV650 Gen1 (99-02) Tech
Top