SV stolen->recovered... how do I get it back on the road? [Archive] - SV650.org

lazymanc

02-04-09, 04:35 PM

Ok, so my SV has been recovered by the police, and I've now got it back.
covered here: http://forums.sv650.org/showthread.php?p=1849232#post1849232

It's in a bit of a state but looks overall repairable, mostly cosmetic damage apart from the top yoke / ignition / gear shift / tank cap.

http://www.lazymanc.com/images/recovered_sv/after1.jpg
http://www.lazymanc.com/images/recovered_sv/after2.jpg
http://www.lazymanc.com/images/recovered_sv/after3.jpg
http://www.lazymanc.com/images/recovered_sv/after4.jpg

I don't know if it starts yet, so the first thing I want to do is make sure the engine runs - err, how? :) Do I need to buy an ignition / key set?

If it does then I think i'll ditch the plastics - can an S be converted into a naked? How much am I looking at for a new front nose if not?

Parts needed to get it running again:
top yoke
ignition
gear shift
fuel tank cap
new chain (it's obviously been left a while cause it's rusted to feck)
sproket set

Cosmetic parts:
top fairing
crash bungs
fairing lowers
rear seat lock

anything i've possibly missed that's obvious from the pics?

simesb

02-04-09, 04:40 PM

The parts wanted section here, and ebay, will be your friends for a while :D

I would concentrate on what you need to get it on the road and secure, then deal with the cosmetics later. Wouldn't convert it to naked either unless you want to do a streetfighter project or something.

Dan

02-04-09, 04:41 PM

At some point you're going to need a tank, looking at it, and a pair of fork caps, bungs, side cover panels as well as a top yoke nut.

That's to get it looking nice, obviously.

Time for a wild streetfighter I'd say.

simesb

02-04-09, 04:43 PM

The fairings look scratched rather than broken - somebody may be able to respray them?

lazymanc

02-04-09, 07:08 PM

The fairings look scratched rather than broken - somebody may be able to respray them?

There aren't any cracks in the lower fairings, but the plastic is pretty badly gouged - might be able to sand them down and respray but they might be too far gone.

The engine casing is filthy but looks intact, and the oil level is still correct so i'm hoping she's still a runner.

Chain is rusted to feck, sprockets not much better, so I'm thinking I'll probably need to replace those, but will give them a scrub first to see if they come clean.

The tyres seem fairly firm, I'm hoping they just need inflating a bit.

Clutch / brake levers are fine, but the clutch cable adjuster bolt (hollow threaded thing the cable passes through near the lever) is snapped.

Gears seem to work, although the pushrod is a bit bent and the peddle is snapped.

I've taken the battery out and got it on a charger, it looks like they've had the seat off a couple of times as the plastic infills and some bolts are missing, I'm guessing they probably started it from somewhere under there?

Ideally I'd like to try starting it tomorrow evening, I'm guessing it's possbile without an ignition otherwise they wouldn't have been able to use it - any ideas? Just to check the engine isn't seized etc before I start spending money.

Nobbylad

02-04-09, 07:22 PM

Last time I looked there were some silver fairings on eBay, just search 'SV650 fairing'.

There's a bloke near me, PSG (in Burscough Industrial Estate), that can repair fairings. Not sure how good he is but he reckoned he could repair my fairings that were pretty badly split, cracked, gouged, scraped.

Gear lever should be about a tenner on eBay, Soulkiss and I got some recently, will try and dig out the link for you.

EDIT: linky (http://forums.sv650.org/showthread.php?t=126858&highlight=gear+lever)

abdul.aziz

03-04-09, 09:57 AM

Dave20046

03-04-09, 10:32 AM

Well done manc police (pete?), I know blue pete had given chase a couple of times. Would have loved for him to get his hand on him.

lazymanc

03-04-09, 12:18 PM

really sorry to hear it got nicked.

My mates bike got nicked in the first week he owned it. after he got it back it was a headache to get everything repaired.

anyway, he couldnt use his keys either because the ignition barrell was damaged, but because the bike was still hot wired we were able to jump start the bike. Can you do something similar?

Yeah basically i need to know how to hotwire it because there's no point paying £50 for an ignition if the engine wont turn, anyone got any pointers?

Dan

03-04-09, 12:23 PM

Yeah basically i need to know how to hotwire it because there's no point paying £50 for an ignition if the engine wont turn, anyone got any pointers?

All you'll need to do is identify which wires are made live when the ignition key is turned to the 'on' position from a wiring diagram or meter testing, connect those wires to live (from the battery) and then hit the run switch, and off it should go.

Alternatively, ask a chav. They'll know.

lazymanc

03-04-09, 12:24 PM

Well done manc police (pete?), I know blue pete had given chase a couple of times. Would have loved for him to get his hand on him.

Not to slate the cops but they were at the address on an unrelated warrant, the bike just happened to be there. Unfortunately the rules for chasing scum on bikes prevent Road Rash (http://upload.wikimedia.org/wikipedia/en/9/91/MD_Road_Rash.png) style takedowns :(

As a side note, please keep this thread on topic (repairing the bike) and use the other thread (http://forums.sv650.org/showthread.php?p=1849232#post1849232) for discussing the theft, cheers.

alexs

03-04-09, 12:28 PM

Guessing from the 2003+ service manual I think you connect together the Red, Orange, Orange/Yellow and Brown in the ignition switch wire loom. Don't blame me if it sets you on fire though ;)

I seem to remember someone here having a rather nice wiring diagram for the SV. Not sure what manual they got it out of though. Does the Haynes say anything about the ignition system?]

If they've trashed it hard enough you might need to bypass the side stand and clutch switches as well I suppose.

lazymanc

03-04-09, 12:30 PM

All you'll need to do is identify which wires are made live when the ignition key is turned to the 'on' position from a wiring diagram or meter testing, connect those wires to live (from the battery) and then hit the run switch, and off it should go.

Alternatively, ask a chav. They'll know.

Ok cool, well i've got a haynes manual that has the wiring diagram in the back, hopefully i'll be able to work it out from that. I charged the battery last night so assuming it's not damaged internally I should be able to get it started...

It's possbile the tank has water in it because the filler cap has been forced open - is it fairly easy to take off the tank and empty / dry out?

Baph

03-04-09, 01:42 PM

Ok cool, well i've got a haynes manual that has the wiring diagram in the back, hopefully i'll be able to work it out from that. I charged the battery last night so assuming it's not damaged internally I should be able to get it started...

It's possbile the tank has water in it because the filler cap has been forced open - is it fairly easy to take off the tank and empty / dry out?

Ignition, I don't have my haynes to hand, but it's blindingly obvious when you look at the diagram.

Tank, obviously the front two bolts to lift the tank, but then I think there's another two bolts (under the rider seat) to get the bracket off. Disconnect the pipe before you attempt to walk away with the tank. :)

Don't leave the inside of the tank damp with nothing in it for too long, otherwise it'll start to rust! Dehumidifier or so to try & dry it out, then use it as intended, to keep fuel in (even if you have to drain & scrap the fuel because it's gone off - that's cheaper than a new tank because it rusted!!)

lazymanc

03-04-09, 03:18 PM

Ignition, I don't have my haynes to hand, but it's blindingly obvious when you look at the diagram.

Tank, obviously the front two bolts to lift the tank, but then I think there's another two bolts (under the rider seat) to get the bracket off. Disconnect the pipe before you attempt to walk away with the tank. :)

Don't leave the inside of the tank damp with nothing in it for too long, otherwise it'll start to rust! Dehumidifier or so to try & dry it out, then use it as intended, to keep fuel in (even if you have to drain & scrap the fuel because it's gone off - that's cheaper than a new tank because it rusted!!)

Assuming the tank has water in and I need to remove it, is it safe to let the starter motor try and crank the engine with no fuel tank attached? Obviously I'm not expecting it to fire into life with no fuel but at least i'll be able to see if the engine turns.

Baph

03-04-09, 03:19 PM

Assuming the tank has water in and I need to remove it, is it safe to let the starter motor try and crank the engine with no fuel tank attached? Obviously I'm not expecting it to fire into life with no fuel but at least i'll be able to see if the engine turns.

I can't see anything wrong with that.

Haynes manual with me now. :) To turn the ignition on, connect the red to the orange, and orange/yellow to black. Heypresto. :)

simesb

03-04-09, 03:20 PM

Assuming the tank has water in and I need to remove it, is it safe to let the starter motor try and crank the engine with no fuel tank attached? Obviously I'm not expecting it to fire into life with no fuel but at least i'll be able to see if the engine turns.

No fuel is fine, but not oil would be v. bad. You may get some FI errors if the wiring has been hacked with.

You could turn the engine by hand if you wanted to....

lazymanc

03-04-09, 03:44 PM

No fuel is fine, but not oil would be v. bad. You may get some FI errors if the wiring has been hacked with.

You could turn the engine by hand if you wanted to....

As in pushing the bike in 1st gear?

lazymanc

03-04-09, 03:45 PM

Oil level seems fine in the sight glass.

simesb

03-04-09, 03:49 PM

As in pushing the bike in 1st gear?

Take the plugs out so there is no compression, and turn the back wheel with it in gear.

lazymanc

03-04-09, 03:58 PM

ok that sounds simple enough, then I can try starting it properly once the tank is re-attached.

Just rang a dealer to find out new prices for a keyset and top yoke... £180 / £170 respectively, W.O.W.

I'll be ebaying for everything I think.

Bibio

03-04-09, 04:11 PM

looks mainly cosmetic, a good sprayer should have it looking like new in no time.

is the ignition barrel fubar (screwdriverd)? or is it just broke off the top yoke?

if you are willing to pay for the postage i have a top yoke and top fork adjusters sitting doing nowt, i will never use them so you are more than welcome to them.

as for a new barrel/keys, ebay is full of second hand sets, that are quite cheep..

i'm gutted for ya mate, i have had 4 bikes stolen in my life and i know what its like to get a recovered one back, but yours seems not to bad to be honest.

i very much doubt that the engine is knackered. they are pretty tough little beggars.

if you can help it dont cut any of the ignition wiring, it will just give you problems in the future.

lazymanc

03-04-09, 06:44 PM

IT LIVES!

Put the battery back in and twisted what was left of the ignition barrel with a big screwdriver... bingo, all the electrics fire up ok.

The tank was off at this point, so I thumbed the starter, the engine was turning over and you could feel the compression coming out of the exhaust.

Re-attached the tank, turned it back on, thumbed the starter and it kicked into life first time :)

So, time to order some bits.

Bibio - that's a really generous offer, thanks. Let me know what you want for them though, even if it's just a crate of beer or whatever, I feel a bit cheeky just paying the postage. PM me with a payment method and i'll get it sent over ASAP.

Shopping List:
TopYoke / adjusters (Bibio - ta!)
Ignition (does this look ok? (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=200321863349))
Gear lever (this one? (http://cgi.ebay.co.uk/03-2003-Suzuki-SV-650-SV650-S-Gear-Shift-Shifter-Lever_W0QQitemZ370104893841QQcmdZViewItemQQptZUK_M otorcycle_Parts?hash=item370104893841&_trksid=p3286.c0.m14&_trkparms=72%3A1683%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318))

Gonna attempt to clean up the chain / sprockets over the weekend but I think i'll be replacing those as well.

kurtis.randle

03-04-09, 06:57 PM

[quote=lazymanc;1849264]Ok, so my SV has been recovered by the police, and I've now got it back.
covered here: http://forums.sv650.org/showthread.php?p=1849232#post1849232

It's in a bit of a state but looks overall repairable, mostly cosmetic damage apart from the top yoke / ignition / gear shift / tank cap.

http://www.lazymanc.com/images/recovered_sv/after1.jpg
http://www.lazymanc.com/images/recovered_sv/after2.jpg
http://www.lazymanc.com/images/recovered_sv/after3.jpg
http://www.lazymanc.com/images/recovered_sv/after4.jpg

I don't know if it starts yet, so the first thing I want to do is make sure the engine runs - err, how? :) Do I need to buy an ignition / key set?

If it does then I think i'll ditch the plastics - can an S be converted into a naked? How much am I looking at for a new front nose if not?

Parts needed to get it running again:
top yoke
ignition
gear shift
fuel tank cap
new chain (it's obviously been left a while cause it's rusted to feck)
sproket set

Cosmetic parts:
top fairing
crash bungs
fairing lowers
rear seat lock

hey what locks where on it when stolen?

Baph

03-04-09, 07:06 PM

IT LIVES!
Shopping List:
TopYoke / adjusters (Bibio - ta!)
Ignition (does this look ok? (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=200321863349))
Gear lever (this one? (http://cgi.ebay.co.uk/03-2003-Suzuki-SV-650-SV650-S-Gear-Shift-Shifter-Lever_W0QQitemZ370104893841QQcmdZViewItemQQptZUK_M otorcycle_Parts?hash=item370104893841&_trksid=p3286.c0.m14&_trkparms=72%3A1683%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318))

Ignition looks fine to me, but that's a curvy gear lever (description says 1999-2003 not 2004+).

simesb

03-04-09, 07:21 PM

Ignition looks fine to me, but that's a curvy gear lever (description says 1999-2003 not 2004+).

And it's from Taiwan. Folks have reported issues with some cheap alloy parts from fleabay, but it'll get you back on the road.

lazymanc

03-04-09, 08:27 PM

hey what locks where on it when stolen?

I'd left it on my drive for litterally an hour with just the steering lock on - stupid looking back but it's not a particularly dodgy area.

lazymanc

03-04-09, 10:05 PM

Ignition keyset ordered.

My SV is a K3 pointy on an 04 plate, so does it use the old style gear lever?

http://cgi.ebay.co.uk/Suzuki-Gear-Change-Lever-GSXR-RF-SV-TL-GSF_W0QQitemZ140307259988QQcmdZViewItemQQptZUK_Mot orcycle_Parts?hash=item140307259988&_trksid=p3286.c0.m14&_trkparms=72%3A1689|66%3A2|65%3A12|39%3A1|240%3A13 18 (http://cgi.ebay.co.uk/Suzuki-Gear-Change-Lever-GSXR-RF-SV-TL-GSF_W0QQitemZ140307259988QQcmdZViewItemQQptZUK_Mot orcycle_Parts?hash=item140307259988&_trksid=p3286.c0.m14&_trkparms=72%3A1689%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318)

that one costs twice as much, worth it?

I need a clutch cable adjuster also, anyone got a part number please? :)
*edit* Part number is 57441-11010 £2.96 from Robinsons... think i'll wait until I've got a full list of bits and bobs to save on postage.

lazymanc

04-04-09, 06:13 PM

Stu

04-04-09, 06:28 PM

Today I've removed all the fairings, rear wheel, exhaust, hanger / gear selector and all the brakes.

I was attempting to remove the chain but I'll need to take the swingarm out... the problem is my abba stand uses the swing arm pivot bolt to hold up the bike. How do you hold the bike up with no swingarm in?

http://www.lazymanc.com/images/recovered_sv/rebuild1.jpg
http://www.lazymanc.com/images/recovered_sv/rebuild2.jpghttp://www.lazymanc.com/images/recovered_sv/rebuild3.jpghttp://www.lazymanc.com/images/recovered_sv/rebuild4.jpghttp://www.lazymanc.com/images/recovered_sv/rebuild5.jpghttp://www.lazymanc.com/images/recovered_sv/rebuild6.jpghttp://www.lazymanc.com/images/recovered_sv/rebuild2.jpg (http://www.lazymanc.com/images/recovered_sv/rebuild2.jpg)
http://www.lazymanc.com/images/recovered_sv/rebuild3.jpg
http://www.lazymanc.com/images/recovered_sv/rebuild4.jpg
http://www.lazymanc.com/images/recovered_sv/rebuild5.jpg
http://www.lazymanc.com/images/recovered_sv/rebuild6.jpg
Why don't you like posting pics as images? is it cos you is lazy? ;)

to answer your questio Abba stands can get an adapter to operate from yo foot peg bolts or something like that
But I wouldn't remove the swing arm if it was me. Cut the chain off if you' not going to reuse it or use a chain breaker. Don't remove it if you're going to use it again

lazymanc

05-04-09, 02:03 PM

Why don't you like posting pics as images? is it cos you is lazy? ;)

to answer your questio Abba stands can get an adapter to operate from yo foot peg bolts or something like that
But I wouldn't remove the swing arm if it was me. Cut the chain off if you' not going to reuse it or use a chain breaker. Don't remove it if you're going to use it again

Correct, I couldn't be arsed re-sizing them to fit the page! I'm actually a web developer so you'd think I'd put the effort in :)

lazymanc

05-04-09, 02:37 PM

simesb

05-04-09, 03:04 PM

As for the swingarm, I think I will take it out cause it all needs cleaning back there anyway. Might as well do it while it's in bits.

The Haynes manual lists a "peg spanner" tool that's basically a socket with 4 opposing pegs to remove the lock nut on the swingarm, but the scrotes have ditched my suzuki toolkit so I don't have one... and Robinsons list it at £90!

Anyone local that can lend me one? :)

You mean one of these (http://cgi.ebay.co.uk/NEW-SUZUKI-SV650-SV-650-SWINGARM-SOCKET-TOOL-se_W0QQitemZ300303448512QQcmdZViewItemQQptZUK_Moto rcycle_Parts?hash=item300303448512&_trksid=p3286.c0.m14&_trkparms=72%3A1683%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318). 'Fraid not...

Stu

05-04-09, 05:02 PM

It was never in the std. tool kit (unless you put one in it?)

lazymanc

05-04-09, 05:16 PM

It was never in the std. tool kit (unless you put one in it?)

I must've misread the manual. Thanks for the ebay link simesb.

lazymanc

05-04-09, 05:39 PM

Gonna drop the forks out and take the yokes off tomorrow, what should I be looking for damage-wise on those parts? Will it be obvious? I guess I'll take some pics and stick them here for an expert eye.

Headrace bearings - are they part of the steering column?

lazymanc

07-04-09, 06:41 PM

Ok, chain and sprocket kit came today. I ordered:
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWNX:IT&item=350183895155

Only they've sent me a 47T rear... (delivery note definitely says 44T) ...and an X ring instead of an O ring.

So, am I a lucky SOB or do I need to send them back for the ones I actually ordered?