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Discussion Starter · #1 ·
I got hold of this 2003 used and abused SV650S now N... ish. 32k miles on the clock and probably been down more times than a $20 whore and carries the same baggage. Wheel Tire Vehicle Land vehicle Fuel tank


Body (what remains) is surprisingly good and whoever did the paint job did decent work (was originally that copper/orange color). It has a list of times that needs to be addressed: Fork seals looked original, steering stops in the forward position (bearing issue) and half the nuts and bolts are from a hardware store (some missing). One rearset is OEM another is aftermarket. Grips are the ugliest option I've ever seen put on a bike. That's just the icing on the cake, much more to come in time.

So I started to break it down.
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Pay no attention to the stands that no expense was spared on... Seriously, I spent nothing. I found an old 2x4 and wondered "how sketchy can I make this".

First to be addressed were the forks. Rusty, rotted and in need of love. Just like that $20... Oh never mind. That mess was one of the dust seals. And yes, I have all the high dollar tools.
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Next to be worked on (and where I'm currently at with the project) is the steering head. It would literally stop in the forward position. How long that's been going on for is a mystery but the fact that peeps rode with like that is mind boggling.

Anyway... I just to get some good grease to pack the new bearing with and I can put the front end back on.
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A little out of order with the pic but next on the list is to rebuild the MC and change the caliper seals. I figure since I'm doing all this other seal work let get the bike as refreshed as possible. I do have a set of brake lines on order since I have a thing against rubber hoses and have issues with OEM's still using them. From there the wheels will be stripped of their custom paint job (really really really bad paint job) and powder coated then new bearings for those too.
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This will be a slow going project as I'm in no rush but I though it would be cool to post about it. :)
 

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Nice opening post Burncycle. You obviously know your way around motorcycle mechanicing. Welcome to SVR, and keep us apprised of your progress.
 

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Discussion Starter · #3 ·
Got a little more time in with the old SV yesterday. The steering head it now back together-ish (I'm waiting for a new upper dust cap before putting the top triple back on. Here you can see where I cut the old bearing cup to push down on the new roller bearings. The cut in the old cup was to get it off easier. New pipe, er press, to get it all seated. ;)
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I knew the radiator was a little hammered but when I took it off it seemed to be a bit more hammered than I was hoping for. Lower mount tab was broken off. The big concern is the fan. Part of the shroud was bent in toward the blades jamming the movement of the fan itself. A quick tap on the shroud and it freed up the fans movement. I just need to test the fan to make sure it isn't burnt out. New radiator on order.
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I replaced the old rubber hoses with silicon hoses, in red, because I'm that guy. A lot of cutting and trimming was required. Hardest part was taking the good scissors from the kitchen. If my wife saw that the project would be over... because I'd be dead.
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Discussion Starter · #5 ·
Only got a chance to do a couple of small things yesterday...

I was able to verify the fan still worked and wasn't burnt out from being wedged against its shroud.
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Block off plates in place.
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Had a look at my high dollar Chinese rear sets (joking about the high dollar part of course). I had to go this route on an '06 MV Agusta Brutale 900 I had. They served me well then and I hope they do the same again. Looks like I need to get a pressure switch for the brakes because for all the bits and pieces in the box in no way help with rigging anything up with the existing spring system. But for less than $100 what should I really expect.
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Somehow, even with just a little bit of tinkering, I still managed with keep things completely disorganized. lol
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Discussion Starter · #8 ·
Got some more time with the SV yesterday. The front end is back on the bike now. With that I can move it on my lift to make life a little easier. I'm old-ish and my back can't do the things it use to.
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The new radiator arrived at the end of the day so that will be next to go on. The calipers are on the table to be rebuilt but I may hold off until the new lines come in... Which I have no idea when that will be. The old aftermarket headlight bucket was just put on to see what I was working with. Its a little buggered but those things are cheap so I may just replace it.

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The Duc's little bro is starting to look like a bike again. :)
 

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Discussion Starter · #9 ·
The subframe is back on now and the eBay radiator is in place. Typical issues with a cheap eBay radiator, 2 of 3 fan mounts needed to be 'manipulated' to work while there was just no hope for the 3rd. Mounting to the bike itself was spot on though (small miracles). The overflow spigot is a different size than the OEM but that's a simple fix.
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Started work on the brakes as well. Rebuilt the master cylinder and will start on rebuilding the calipers next. New brake line was also test fitted (see above). Just running a street (OEM) configuration for the lines to keep it simple.
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Discussion Starter · #10 ·
Worked on the calipers over Thanksgiving. The pistons were removed via compressed air. One of the calipers needed about 80psi to pop out. Little bastards were wedged in there. The amount of crud sludge was a little disturbing. Little elbow grease and a lot of brake cleaner and everything cleaned up nicely. System was bled and is good to go...er... stop!
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Throttle bodies are back on, pair valve removed from the airbox (hole plugged) and the system fooled (plug and play kit). New air filter in place too. Got some new hose and fittings to convert from the larger overflow spigot from the radiator to the OEM hose size.
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Coming along nicely. Two questions: Why is there material wrapped around the exhaust? And, your motorcycle stand/lift looks really handy. Where did you buy it? Thanks, and keep up the great write up.
 

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Discussion Starter · #12 ·
Coming along nicely. Two questions: Why is there material wrapped around the exhaust? And, your motorcycle stand/lift looks really handy. Where did you buy it? Thanks, and keep up the great write up.
One of the former owners thought it would be a good idea to use the header wrap. Unfortunately no love has been given to it over the years so it looks like shit. I will be removing it but it just hasn't made the to-do list yet. But... I will be replacing it. The old hot-rodder in me is the reason why, no actual real reason other than I want to.

The lift is from Kendon. I've had this one for about 15 years now. Here's a link to their site... https://www.kendonusa.com/collectio...ding-sport-bike-lift-folding-motorcycle-lifts
 

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Discussion Starter · #13 ·
Starting to come together! I still have a lot of work to do but I am getting close to getting to a point in which I could fire it up.
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Discussion Starter · #14 ·
I finally got a new battery charged up and coolant added in the radiator. Hit the ignition and I'm greeted with the FI flashing... C23 (Tip Over Sensor (TOS)). I'm scratching my head because even though its been over a year since its been started it was running just fine before I started this little project. I take the sensor off and can feel the 'trigger' part still rotating inside it. I broke out the service manual and tested the voltage and resistance and sure enough its hitting the voltage for when its triggered. Service manual says replace, I say lets fix it. I open it up (easy to do) and see that it has a bit of corrosion on the contact points. A bit of PJ1 cleaner and a soft toothbrush and its looking good as new. Install it and still C23... UG...hold on... Install it right way up, no more C23. lol
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Discussion Starter · #18 ·
Sounds good. Nice color!
A pipe will be going on (probably a Delkevic). It had a V&H pipe on it but it took a beating from the one of the prior owners. Its a nice color but only a OK paint job. One of the future projects will be to repaint it again.
 

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Discussion Starter · #19 ·
Not much done in the last few days. I'm waiting for a few things to come in before I can do much. I did just get a new throttle tube in to replace the torn up one that was on the bike. Lubed the lines since had the chance too.
 

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Discussion Starter · #20 ·
I got a cheap little fly-screen in. I'm going to use this to also support the gauge pod with a couple of custom brackets. Now I'm hoping Santa takes note of my Amazon wish list and I can finish up the first phase of this 'fix-it' project. :)
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