SV Winter Project - Suspension and other stuff [Archive] - SV650.org

DarrenSV650S

29-12-07, 05:01 PM

I thought I'd post up what I'm doing to the sv this winter.
I've got gsxr forks to put on. I've been trying to find a gsxr front wheel for ages but they are like hens dentures. But hopefully one will be arriving next week, along with an abba stand.
The plastics are all going to get sprayed, along with the new gsxr mudguard and possibly a new undertray if funds allow.
And eventually, once funds are available I'll be getting an ohlins rear shock.

So far I have completely stripped down the new calipers and fitted new seals and pads
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0008.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0007.jpg

The forks are ready, just need the wheel and discs
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0006.jpg

Been working on it today. All the plastics are now off except the mudguard.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0001.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0002.jpg

I'm trying to keep all the bolts etc in separate bags to make it simpler when I'm putting it back together
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0003.jpg

Nose fairing needs a little crack welded
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0005.jpg

I'll update this as I go

Stig

29-12-07, 05:09 PM

Cool. I have plans too. But I had the same plans last winter :roll:

Look forward to seeing the finished job.

Richie

29-12-07, 05:26 PM

http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0002.jpg

I'm trying to keep all the bolts etc in separate bags to make it simpler when I'm putting it back together

But you might get the plastics mixed up if your not careful. ;-)

Looking forward to seeing your finished bike.

ps, Carnoustie... I was up there two years ago with the Royal Engineers, putting a roof on some old barn on a gun range. how far is that place and what is it called as I seam to have forgotern?

DarrenSV650S

29-12-07, 05:56 PM

Do you mean barry budden?

Richie

29-12-07, 08:07 PM

Do you mean barry budden?
Thats the place.

I was at Meigle at a looking after the plant equiptment and other machinary, for the month we were there.
nice people.:thumbsup:

DarrenSV650S

29-12-07, 08:27 PM

I remember I had to deliver pizza's to some of the troops at barry budden. I broke the shops record for the longest ever delivery. I was driving around all night in the pitch black over bumpy pot-holed "roads" trying franticly to find the place. Complete maze that place

Richie

30-12-07, 01:17 AM

Never mind as I never did get it......
as I was out in Dundee trying to get off with some MILF ... very tasty yummy mummy. IRRC

Devil Biccy

30-12-07, 10:28 AM

Doh!!! bag idea an excellenty one why oh why did I not think of that before taking all the plastices of my bike!

I'm reparing a K5 including forks/rear subframe etc but it'll be a very slow project. I think I'll take photo's of the Alarm wiring around the rear sub before dismantling

chunkytfg

01-01-08, 08:18 AM

Devil Biccy

01-01-08, 01:16 PM

is the rear subframe bent? if so do you need a new one? I have one

Got one thanks

DarrenSV650S

03-01-08, 09:58 PM

Got some of this plastex stuff today to repair the crack in the nose
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0009.jpg

It starts to set very quickly!:eek: Had to work pretty quick

Just have to wait till its properly cured now and see what its like

Oh and the gixxer wheel arrived:cheers: and so did the abba stand. So I think that just leaves me to get discs. And the wheel will need either powder coated or painted, can't decide which.
And then I'll be ready to start the swap!:D

Devil Biccy

03-01-08, 10:40 PM

DarrenSV650S

04-01-08, 12:12 AM

Where from and how much as I have a headlight tab to rebuild!
Well the plastex website is here:
http://www.plastexexpress.co.uk/plastex_kits.htm

....but it just redirects you to bathroomexpress here:
http://www.bathroomexpress.co.uk/acatalog/2101.html

and the only kit they have is the small kit, so I don't know where you would get the bigger kits. But to be honest there was more than enough in the small kit anyway.

Where did you get your Rocha undertray from?:D

Devil Biccy

04-01-08, 09:44 AM

Cheers will order some today trying to get the blue stuff or a big bottle of clear.

As for undertray it came with the bike PM Plowsie or Billy ( He made all the Mods) they will know HTH

andyb

04-01-08, 10:03 AM

Oh and the gixxer wheel arrived:cheers: and so did the abba stand. So I think that just leaves me to get discs. And the wheel will need either powder coated or painted, can't decide which.
And then I'll be ready to start the swap!:D

I'd go for the powder coating. I did mine at work and they look great (apart from I made the wrong colour choice). I asked a while ago on here about painting them but the general concensus was that it wouldnt be hard enough and would chip easily.

HTH

DarrenSV650S

06-01-08, 04:46 PM

Cleaned up the engine today with some of that S Doc stuff. Quite impressed with the results. It even cleaned the downpipe.
Before and after pics:

http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0001-2.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0004-1.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0002-2.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0006-1.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0003-1.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0005-2.jpg

I was going to give the engine another spray but I dropped the bottle and the skoosher bit broke, so I'll need to get a replacement.

Also removed the front brake and got the tank off
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0007-1.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0008-1.jpg

Seriously running out of space in the shed :lol:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/SV/DSCF0009-1.jpg

DarrenSV650S

29-01-08, 08:19 PM

Got a fenda extenda. I've also got some TL1000s clip ons now and I got second hand gsxr discs.
So basically, I think I've run out of excuses not to get started on the forks http://carnoustiebikers.co.uk/forum/images/smiles/icon_rolleyes.gif

.....oh wait I need grease!

I'm trying to get a hotbodies undertray, but M and P aren't being very useful by email so I'm gonna phone them tomorrow, because I can't take the panels to the sprayers until I get that. And I also need to drain the tank.

Wideboy

29-01-08, 08:23 PM

flippin heck the motor came up nice, i gots to gets me some of that :cool:

Wideboy

29-01-08, 08:26 PM

is this (http://www.motohaus.com/acatalog/SDOC_100.html) the stuff?

DarrenSV650S

29-01-08, 08:29 PM

Yeah thats it. It's brilliant

Wideboy

29-01-08, 08:34 PM

your next mod will be to autosol that exhaust :lol:

DarrenSV650S

29-01-08, 08:36 PM

Oh no. Been down that road. Complete waste of time and effort.
Besides, look what the s doc did to it! All I need to do is give it a skoosh every now and then

sortid

Rich

30-01-08, 06:20 PM

Did the engine come up that good without scrubbing as it advertises, or was there a little elbow grease involved?

Have you told us what colour your doing it yet or is it a suprise?

Rich

DarrenSV650S

30-01-08, 07:12 PM

Rich

30-01-08, 07:22 PM

I wiped it with a sponge, that was all. I'm keeping the bike standard silver just because I think it suits it with the silver frame

I've been reading through the haynes tonight trying to get ready for the fork swap.
Do I need to remove each fork individually? Or could I just keep them attached to the bottom yoke and wheel?

Yeh good idea with the silver, looks good and keeps cost low as posible. I might have to get some of that cleaner looks a good finish for little effort, just the ticket.

As for the suspension i'd have imagined you could keep them together as long as you can raise the front end high enough to drop the forks out. Top yolker off ofcourse. I'm just guessing and hoping that it would work that way as it save messing too much. Wait for an expert to come along.

DarrenSV650S

30-01-08, 07:26 PM

Now that you mention it, I'll probably have to take off the wheel to give me space to drop the forks

phil24_7

01-02-08, 12:06 AM

I used an ABBA stand and strung the front up on to a rafter. Doing it this way I was able to (just) manage to get the whole front end off in one, then replace with the complete 600 front end in one. Saved a lot of hassle.

DarrenSV650S

01-02-08, 05:39 PM

Ahh cheers for the info Phil

phil24_7

02-02-08, 04:56 AM

No probs, just ask if you have any other queries or problems.

Regards

petevtwin650

02-02-08, 07:59 AM

Are you not going to change the oil at least in the forks before putting em on?

DarrenSV650S

02-02-08, 10:50 AM

In the new forks? no

phil24_7

02-02-08, 02:37 PM

If the new forks are high mileage or if any of the seals are knackered then they'll need it. I was lucky, mine were mint and low mileage!

DarrenSV650S

02-02-08, 07:37 PM

I'll try the forks out and see how they feel. If they need replaced then so be it

Phil what bearings did you use? Is it the sv's or the gsxr's size? Or are they both the same?

Stig

02-02-08, 08:16 PM

For the cost of new oil, I'd change that before fitting the forks as a matter of course.

Rich

02-02-08, 08:32 PM

I'll try the forks out and see how they feel. If they need replaced then so be it

Phil what bearings did you use? Is it the sv's or the gsxr's size? Or are they both the same?

I've been told they're the same bearings, wait for phil to answer though just to be sure. I think it states so on this site phil gave me. http://gregmli.blogspot.com/search/label/DIY

p.s which forks have you got Darren?

DarrenSV650S

02-02-08, 09:15 PM

For the cost of new oil, I'd change that before fitting the forks as a matter of course.
Is it tricky to do?

I've been told they're the same bearings, wait for phil to answer though just to be sure. I think it states so on this site phil gave me. http://gregmli.blogspot.com/search/label/DIY

p.s which forks have you got Darren?
K4 gsxr600 forks

Stig

02-02-08, 10:22 PM

Is it tricky to do?

Only if they were fitted to the bike. The fiddly and tricky part is getting the forks off the bike. Seeing as your starting with them already loose, your on to a winner. Just take the caps off the top, drain the oil put new in, put caps back on.

OK it's a bit more detailed than that but essentially that is all there is to it. The time consuming bit is taking the forks off and putting them on again. In your case, your just doing a simple oil change before fitting them.

petevtwin650

03-02-08, 12:14 AM

For the cost of new oil, I'd change that before fitting the forks as a matter of course.

+1

phil24_7

03-02-08, 05:02 AM

That's it, everybody pipe up and say to change the oil before fitting, AFTER I've already fitted mine!!

Cheers!

The bearing for that front end and your bike are exactly the same so fit whichever you like.

DarrenSV650S

03-02-08, 01:05 PM

Cheers again!
I'm going to try get bearings, oil, seals etc on monday

phil24_7

03-02-08, 02:34 PM

Why aren't you re-using the bearings from you SV?

Stig

03-02-08, 02:44 PM

Why aren't you re-using the bearings from you SV?

Maybe the same reason as he's going to change the fork oil :wink:

phil24_7

03-02-08, 03:13 PM

Bah humbug, guess I'm just a cheap skate!!

petevtwin650

03-02-08, 04:17 PM

Bah humbug, guess I'm just a cheap skate!!

After what you paid your "mate" for the Gsxr bits we already know you are. :p:D

phil24_7

03-02-08, 04:31 PM

That's a fair point, he's still talking to me though so he's not upset bout the price he got!

DarrenSV650S

03-02-08, 04:46 PM

Why aren't you re-using the bearings from you SV?Maybe the same reason as he's going to change the fork oil :wink:
I wasn't going to (just out of ignorance) but I have been advised to change them just as a matter of course, because the cost of new ones isn't too much

So, what I need is new bearings and tracks, new oil and new seals

Can anyone think of anything else? Do I need to replace the guides in the forks?
Oh and how much oil will I need roughly?

DarrenSV650S

03-02-08, 04:47 PM

Oh and Phil, have you got the tool to remove the wheel spindle? It's a HUGE big hex shape. Where did you get it?

Lissa

03-02-08, 04:57 PM

Oh and Phil, have you got the tool to remove the wheel spindle? It's a HUGE big hex shape. Where did you get it?

This is the kind of thing you need. Available from E Bay:D

http://cgi.ebay.co.uk/Motorcycle-Spindle-Tool-22mm-24mm19mm-LASER-3933_W0QQitemZ320181897611QQihZ011QQcategoryZ36796 QQtcZphotoQQcmdZViewItem

DarrenSV650S

03-02-08, 05:01 PM

Nice one Lissa cheers. I'll buy one now

Stig

03-02-08, 05:49 PM

This is the kind of thing you need. Available from E Bay:D

http://cgi.ebay.co.uk/Motorcycle-Spindle-Tool-22mm-24mm19mm-LASER-3933_W0QQitemZ320181897611QQihZ011QQcategoryZ36796 QQtcZphotoQQcmdZViewItem

Are you sure :?: Bit of an ambiguous title if you ask me. :wink:

DarrenSV650S

04-02-08, 06:02 PM

Took the forks to the shop today to get new oil and seals. And I ordered the bearings

DarrenSV650S

07-02-08, 09:45 PM

Got the forks back today. Stripped, cleaned internals, stantions and legs. New seals. Bled damper rods etc

phil24_7

08-02-08, 05:03 AM

Hurry up and start building it god damn you!

DarrenSV650S

08-02-08, 05:49 PM

Hurry up and start building it god damn you!
Shut up everyone is saying that! :lol:
The wheel isn't painted yet so I have to wait for that, and then get the tyre put on. It's hard to get stuff done when I can only get to the shops at the weekend. Hopefully the painter will be working tomorrow morning so I can drop the wheel off.

phil24_7

09-02-08, 05:20 AM

By the time you get round to doing it, we'll all have moved onto hover bikes running on renewable fuel that reverses the greenhouse effect! ;-)

DarrenSV650S

09-02-08, 03:18 PM

I'm no in any rush since the good weather hasn't arrived yet. The undertray from M and P will still be about a month! Then everything will go in for painting. I took the wheel in today to get painted but he is very busy. He said he'd try fit it in between jobs.

glade

12-02-08, 07:58 PM

what are you doing about the speedo sensor?

DarrenSV650S

12-02-08, 09:35 PM

what are you doing about the speedo sensor?
phil24_7 has shared his secrets with me;)
see here (http://forums.sv650.org/showpost.php?p=1396937&postcount=7)

glade

13-02-08, 10:15 AM

phil24_7 has shared his secrets with me;)
see here (http://forums.sv650.org/showpost.php?p=1396937&postcount=7)

Is it accurate? Does the number, and radius of the magnets give the same pulses as the original sensor?

I guess there is no way of calibrating the speedo - X pulses = Y distance travelled?

This looks like a really good mod! I'm keeping an eye on ebay!

DarrenSV650S

13-02-08, 11:46 AM

You get the sensor here (http://uk.farnell.com/jsp/search/productdetail.jsp?sku=1225630)

DarrenSV650S

17-02-08, 05:35 PM

Took off the rear subframe today. It is in need of a spray, you can see where the paint has been scratched off by things knocking about under my cowl. So hopefully the painter will be able to fit that in too [-o<

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0003-2.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0004.jpg

I also finally drained the tank (into the car) and removed the tank protector and warning stickers. And removed the warning sticker from the frame that you can see in this pic
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0002-1.jpg

phil24_7

19-02-08, 02:30 PM

Is it accurate? Does the number, and radius of the magnets give the same pulses as the original sensor?

I guess there is no way of calibrating the speedo - X pulses = Y distance travelled?

This looks like a really good mod! I'm keeping an eye on ebay!

You need to mount 4 magnets to the disc and the sensor sends a signal everytime it passes over one, nothing else needs to be done and if you look at th3gr33k's sig it links to a page that'll tell you how to wire the sensor up.

Regards

DarrenSV650S

23-02-08, 02:24 PM

Been working on the new speedo sensor mount. Got a bit of scrap metal from work and made it from that.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0002-3.jpg

Attached the new sensor
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0005-2.jpg

Then onto the forks
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0006-1.jpg

It will be hidden by the mudguard when it is put on. Then just need to splice the new sensor into the existing wiring
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0008-3.jpg

I think I will spray the piece of metal black to protect it and help blend in with the forks
I am waiting on magnets and holders being delivered to put into the disc.

Rich

23-02-08, 03:54 PM

Looking good, glad your doing all the hard work for me Darren should be an easy job for me when you've done. Getting it on with the mudguard there is suppose to be the fun part.

DarrenSV650S

17-05-08, 09:40 PM

Ok I've finally been able to get going at this again. Haven't been able to do it for a while.
Actually have the bike in a garage now rather than a shed, making it a lot easier to work on. Been getting the forks off today

Bike on abba stand and strapped up-
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0042.jpg

Forks out-
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0043.jpg

Then the hard bit was getting the old bearings out, what a nightmare. Got there in the end though, after a lot of wd40 and a LOT of hammering
Then got the new lower race in place-
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0045.jpg

Got a problem with the top one though (see thread in sv tunning)

DarrenSV650S

20-05-08, 09:19 PM

phil24_7

20-05-08, 11:41 PM

Rich

21-05-08, 06:59 AM

Got the new top bearing today and fitted it and the forks. Got the clip-ons on and some of the switchgear. I'm gonna have to drill a new aligning hole in the clip-on for the switchgear.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/20-05-08.jpg

Looking good, i had to do the same re drill a hole for the switch gear to get the grip on. I also had to file down the left clip-on abit where the brake clamp/braket goes on, it just allows the extra 5mm needed to get the bar ends flush. Hows the bodywork going, is it back up to standard yet? Keep us updated!! :cool:

Rich

DarrenSV650S

21-05-08, 08:10 PM

Just a note on fitting the sensor with the mudgaurd on. Fit the gaurd on with longer mudgaurd bolts so you can make sure they will go right through to the nut on the other side of you bracket. Remove the gaurd and refit the bracket. Not liquid metal/jb weld the nuts on (making sure you don't get any on the bolt), wait for it to dry then remove the bolts.

Now you wont need to hold a spanner on the back of the nut when fitting everything back in place.

HTH
Thanks for the tip Phil:)

Looking good, i had to do the same re drill a hole for the switch gear to get the grip on. I also had to file down the left clip-on abit where the brake clamp/braket goes on, it just allows the extra 5mm needed to get the bar ends flush. Hows the bodywork going, is it back up to standard yet? Keep us updated!! :cool:

Rich
I found the same problem with the left clip-on. Thought about filing it down but didn't want to make a mess, so I have ordered a TL1000S clutch assembly off ebay. Hopefully that will sort it.

I was planning to respray all the body work but the painter is very busy just now so it would take far too long and waste even more of the summer. So that stuff will have to wait till next winter. He said the wheel will "definitely" be finished for this weekend:rolleyes:. So I'll leave it a couple days for the paint to harden then I can get the new tyre on and get the bike off the roof! :lol:

Still waiting on the ohlins shock getting set up and delivered from Steve Jordan

Tonight I got the callipers on and the hoses. Still to bleed them, think I'll need some new washers though

DarrenSV650S

24-05-08, 03:09 PM

Got the wheel back this morning :cheers::D
Looking very bling :cool:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0052.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0053.jpg

Also got the new clutch lever which fits much better, leaving plenty room for the switchgear. But the electrical connector isn't the same type. Does anyone know what it is for or if its essential?
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0054.jpg

I bled the brakes too, but when I put the rubber bungs on the bleed nipples some fluid came out of the nipple thread nearest the calliper. Is that normal?

Gonna wait a few days before getting the tyre fitted
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0055.jpg

DarrenSV650S

24-05-08, 04:18 PM

Just realised the switch on the clutch will be for when you start the bike, because the clutch has got to be pulled in or it won't start. So I'll need to find a TL connector

kwak zzr

24-05-08, 04:56 PM

just bypass the switch. bikes looking good matey:)

DarrenSV650S

24-05-08, 08:05 PM

Thought about just bypassing it, but then I found a site by accident when I was looking for a connector for the TL clutch switch. It says that bypassing it can affect the ECU somehow. Don't know if it would be the same for the SV but I'd rather leave it on if I could

Here's the site:
http://www.wotid.com/tls/content/view/18/56/

falc

25-05-08, 06:19 AM

Looking great that is Darren, very nice and especially the tasty forks :cool:

DarrenSV650S

04-06-08, 07:18 PM

Got the new clutch lever connector today and spliced it in. Also got a call saying the new shock is getting posted tomorrow, so I took out the standard shock tonight. Just waiting on the tank and the plastics getting painted now.
I'm gonna wait to do the speedo sensor once I get the mudguard so I can see the cable route and how long it needs to be. I've also still to tap a thread into the magnet holders, which I'll be able to do once the tap and dyes are delivered.

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0022.jpg

DarrenSV650S

06-06-08, 08:36 PM

Got the ohlins shock today :D :p Been fitting it tonight
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0023.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0024.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0025.jpg

Also got the tap and dyes today, so I got the magnet holders done for the speedo.

These fit into the rivets of the brake rotor:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0028.jpg

Drilled and taped:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0030.jpg
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0031.jpg

On the disc:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0032.jpg

Then glued in the earth magnets:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0033.jpg

I've got the bike booked up with Bob Grant in a few weeks to get the suspension set up. Just waiting on the fairings now

phil24_7

07-06-08, 05:10 PM

Ooh, Ohlins *drool*, pretty.

Who do I gotta sleep with to get one of them??

DarrenSV650S

18-06-08, 08:53 PM

Back in business :p:D:cool: ........ FINALLY :lol:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0007.jpg

Took it out tonight, my god I'm out of practice. Riding like cr*p. :o
Did about 60 miles and was starting to feel more comfortable towards the end. But the rain and new front tyre didnt help. Just need more time

The bike feels so much better though. A lot smoother ride and the bike doesn't bounce about now. And the forks don't dive down when I'm braking.
One thing that was a bit weird was when I was doing about 30mph on a straight, the bike just wouldn't keep straight. Its hard to describe but it felt like the wheel kept turning from side to side very slightly. It's maybe just the new set up and I need to get used to it. It could be because the steering is sharper now, I don't know.