Gsvxr-650r

[Kuku]

Hello again from Bulgaria :smt039

First, of course, I want to excuse for my english - not so well at all, especially in terminology.
Than I want to introduce my future project to you....
As the title says - SV650+GSXR+R = "GSVXR-650R" :king:

- Complete front end from "GSXR-600/750" K5 (forks, triple trees, clip-ons, brake calipers, switches, steering damper, front wheel).
- Headlight and headlight fairing from "GSXR-1000" K6 (would be modified a little, because is too wide and don't look so well to me).
- Front/rear racing hoses from "Goodridge".
- Wave front/rear brake discs from..... China :rolleyes: (I know, I know - let me try).
- HH Sintered brake pads from "EBC".
- Rear brake caliper from "GSXR-1000" K4 - IF successfully modified.
- Rear wheel from "GSXR-600" K5.
- Rear shock absorber from "GSXR-600" K5 (or some "Ohlins" if I can luckily buy one from Ebay under £200).
- Front/rear sprockets with DID gold chain.
- Adjustable rearsets, but not nessesary for "SV" - I'll make mounting brackets anyway.
- Adjustable levers.
- Speedo sensor from "GSXR" on the front sprocket.
- K&N Air filter.
- Steering damper "Ohlins", to replace the original.
- "GSXR" carbon fiber front mudguard - yesterday bought one from Ebay.
- "SV" rear mud guard with chain guard - I'll try to find out this in carbon fibre too.
- Belly pan.
- Seat cowl.
- Frame crash protectors with spindel through the frame and engine.
- Crash protectors for front and rear axle.
- LED turn indicators.
- Eventualy.... "Scottoiler".
- Powder coating the frame, swing arm and wheels in black.
- The color of the bike will be black too (metallic or mat) with gold forks, gold brake calipers, gold levers and gold rearsets.

Of course, I'll forgot something now, but will add in progress.

Last weekend I made the bike totaly naked, and from this....
http://img193.imageshack.us/img193/6499/1pa240010.th.jpg (http://img193.imageshack.us/i/1pa240010.jpg/)

...became to this.
http://img193.imageshack.us/img193/7008/1pa240026.th.jpg (http://img193.imageshack.us/i/1pa240026.jpg/)http://img193.imageshack.us/img193/9929/1pa250050.th.jpg (http://img193.imageshack.us/i/1pa250050.jpg/)

As friend of mine says "There's no difference - it's naked anyway!" :-D

So, here is my homework for next weekend - clean and service front end and rear shock.
http://img197.imageshack.us/img197/7500/1pa240041.th.jpg (http://img197.imageshack.us/i/1pa240041.jpg/)



NOW, of course, i need some help to do all this stuff.... :oops:
- Is there any problem with powder coating the frame, swing arm and wheels? I know that powder coating heats the aluminium over 200 degreese Celsius.
Or just paint them with (acrylic-some-thing) paint?
- Same question is about forks and brake calipers? Honestly I don't like gold realy. If it's possibly I'll make them black too.
- And THE most serious question here - can i replace the "SV" swing arm with "Ducati 748/916" single side swing arm?
I know that Triumph/RC30 single side swing arm fits to the Curvy, but to Pointy?
I found some awesome threads in SVRider and TLZone but there is nothing for Pointy... or i can't find it.
- Just wondering, is there any sense of AirBox modifications with K&N air filter and iridium spark plugs, but without nothing else?

I have some more questions, but they are not important in this time...

Thanks a lot for patience and thanks in advance for hepling me to make one different bike :king:

[plowsie]

- And THE most serious question here - can i replace the "SV" swing arm with "Ducati 748/916" single side swing arm?
I know that Triumph/RC30 single side swing arm fits to the Curvy, but to Pointy?
I found some awesome threads in SVRider and TLZone but there is nothing for Pointy... or i can't find it.

Good question, the mods I have seen are with a VFR750 swingarm, don't think I have seen one with a 748/916 Swingarm(though I have seen someone use a Ducati wheel), the best thing to do is to search for Tygaboy on SVrider, he has a thread to walk through the Single sided Swingarm I think.

[hindle8907]

:thumleft:Looks like a cool project but i dont know anything so i cant help you ... Good luck.:thumleft:

Who needs expensive stands when you have got couple of creates eh ?

[maviczap]

Hi,

1. No problem powder coating the wheels, swing arm or frame, but you must remove all the bearings and make sure no powder coat gets into the bearing housings, otherwise you'll have a hard job getting them back in! A decent powder coater will mask or plug the holes where the bearing go, but it gets everywhere.

2. Front fork legs are ok to powder coat ass well, as are the calipers, but you'll need to be extra careful with the calipers and take them apart and remove the pistons & seals and other parts. So it might be easier to paint them. There is a thread on Svrider about painting calipers.

Don't bother with iridium spark plugs and K&N is ok, but a BMC filter is better

Can't help you with the single sided swingarm question though

Here's my swingarm in silver chrome powder coat

5510

[rowdy]

You have forgot to mention anything about exhaust system, you need a decent system if your doing all this other work to the bike, you will get better results with a different air filter and exhaust rather than just changing air filter, although some would suggest a BMC race air filter is better than a K&N filter.

[Kuku]

O'k, I'll keep searching for single side swing arm threads.
Until than i have a lot of work to do with the bike - frame, wheels, front end, calipers....
I don't forgot the exhaust, just need to decide what to do with the swing arm and than will think about exhaust ;)
At this moment the exhaust is something like "custom", it SOUND (http://www.youtube.com/watch?v=O2l0bB6CvPI)s good, but is not so well made and it's look ugly unfinished - I need to grind it and paint it.... IF finaly stays on the bike.

Thanks a lot guys 8)

[svdemon]

I'm interested to see how you get on with the speedo driving off the front sprocket. Do you have any info on this yet? I want to do this on mine.

[Kuku]

With the original "GSXR" speedo sensor and with a little bit more assiduously than the example ;)

http://www.runes-mc.dk/artikel.asp?ArtikelId=12

[Alpinestarhero]

Just one thing - the rear brakes on an SV are really good, so you might be better off retaining the SV caliper. My dad says his rear brake on his K6 GSXR750 is a bit crap.

[svdemon]

With the original "GSXR" speedo sensor and with a little bit more assiduously than the example ;)

http://www.runes-mc.dk/artikel.asp?ArtikelId=12

Any chance of that article in English? Is that in Danish? I'll put it through a translator and see what comes out.

[svdemon]

I wonder if the SV1000/GSXR cable will plug into the SV650 clocks? Or i could put SV1000 clocks on my 650 and install the speedo set up off that. Mmmmmm OEM

[Kuku]

I have no idea what language is this. According to .dk. in the link I suppose it's Danish.
Don't know how this speedo-conversion works - must compare the jacks and than figure it out.
New clocks is.... I didn't think about this.... :rolleyes: Why can't I put clocks from "GSXR" after 2006 with gear position indicator?!
Now thinking about Brembo front and rear master cylinders from "Yamaha R6/R1" after 2006 - a friend of mine recomended this upgrade?!

[beabert]

That is indeed, i have spent many months there, well norway. and no i cant translate it lol,

[svdemon]

It looks as if you stick a 4 magnet nut on with the front sprocket and then mount the sensor next to it. Then it may be a case of using a speedo healer. I'm going to use this set up on mine so i'll update once i get parts etc.

[Rune]

The article is in Danish. The guy who wrote it is a member of the Danish SV-forum http://www.svrider.dk. He is called Runes-mc.dk on there.

Anyway, what you need to do the conversion is:

-Speedosensor off a GSX-R or SV1000
-Speedorotor off a GSX-R
-Speedohealer (Go to www.speedohealer.com (http://www.speedohealer.com))
-A M8x20mm bolt for the rotor, preferably unbraco
-A M4x20mm bolt + lock nut for the clutchcabel/-arm
-A M5x15mm bolt + Lock nut for the speedosensor

Tools and stuff:

-3-8mm metal drillbits as good as possible!
-M8 thread cutter
-Grinding stone (Or a file)
-Electric wire
-Shrinkflex
-Soldering iron and solder
-Cabelstrips
-Files, round and flat

[Kuku]

Thanks a lot Rune :)

I just take the brake discs from customs.
Looks good, but "looks" and "works" are two different things :)
We'll see....

http://img689.imageshack.us/img689/7585/discs.jpg
http://img175.imageshack.us/img175/3222/discy.jpg

[Kuku]

Guys, I have one (maybe stupid for some of you) question...
Can i mount radial front calipers from "GSXR" K5 to non radial front forks of "GSXR" K2 ?
I know that can't do this directly, but the question is - do I ahve any chance to do this with some spacers or something....?!

Thanks!

[Sideshow#36]

No, sorry they just wont fit.

[yorkie_chris]

You could with some custom bracket, I've seen it done. But you lose all the advantages of low unsprung weight and rigidity.

[Kuku]

My point was a pair of cheap "Ohlins" forks from "GSXR-1000" K2, but obviously it's too difficult :?

Thanks, guys!

[yorkie_chris]

What's the point? Performance wise you could valve your forks to work as good as any.

Stock GSXR1000K1-3 are not ohlins, they are kayaba.

[Kuku]

I mean that I found a cheap pair of "Ohlins" forks for "GSXR-1000" K1/2 and just wondering - can I put them together with other K5 parts on my bike....
But you are right! -It's not reasonable anyway.... :)

[yorkie_chris]

A mate of mine got some cheap "ohlins" forks for same bike... we opened to see what (maybe new shiny cartridges etc)... turns out fork was stock just had ohlins springs and a sticker :-P

[Kuku]

No, these (http://img8.imageshack.us/img8/5193/ohlins.jpg) are real "Ohlins" for GBP 330.00, but already gone :)

[Kuku]

Well, the frame goes to "acrylic-mat-gloss-metallic-mix-something" paint job, that the dyer told me, will be absolutely like original but with prescription of him self :?

http://img20.imageshack.us/img20/3065/1image777.th.jpg (http://img20.imageshack.us/i/1image777.jpg/)

He show me two bikes - "Hayabusa" and "GSXR"-K6 painted with this mix-paint and i think they looks great! When the frame is dry it looks mat-black, but when splash it with water it looks metallic :?
He guarantied, that the paint wouldn't scuff or chip from the boots, shingle or something.... BUT i prefer to buy a frame protectors like this (http://img94.imageshack.us/img94/1889/36721811.jpg).

Next will be the wheels, but first must straighten out and clean them.

http://img20.imageshack.us/img20/6963/pa140029.th.jpg (http://img20.imageshack.us/i/pa140029.jpg/)
http://img5.imageshack.us/img5/9066/pa140024.th.jpg (http://img5.imageshack.us/i/pa140024.jpg/)


Now is the bad news....
My top yoke is cracked :(

http://img4.imageshack.us/img4/7543/pb080001n.th.jpg (http://img4.imageshack.us/i/pb080001n.jpg/)
http://img22.imageshack.us/img22/6043/pb080004n.th.jpg (http://img22.imageshack.us/i/pb080004n.jpg/)

It's not much and some people told me to weld it... but i prefer to buy new one.

[Alpinestarhero]

I think tis better to buy a new one, its gonna be a somewhat stressed part aqnd bumps and stuff may only make it worse

looking good so far though

[Kuku]

Thanks.... I'm looking for new one, but is hard to find with reasonable price :?

Now I have two other questions...
Will the "GSXR-1000" K4 brake and clutch levers fit to "GSXR-600/750" K5 master cylinder and clutch?
And can i use the "SV" rear sprocket with "GSXR-600" K5 rear sprocket carrier?
The "SV" rear brake disc is identical with "GSXR" one and fits perfect on the "GSXR" wheel, but are the rear sprocket mounting bolts identical?
In Vortex site there is different part numbers for "SV" and "GSXR" rear sprockets, but i think that the difference can be only in mountin bolts :?

[kwak zzr]

That cracked top yoke is the part where the ignition barrel fixes to it isnt it? had the bike been stolen? usually trying to break the steering lock off a bike cracks this like as yours in the photo.

[Kuku]

I bought a complete front end from USA (ebay.com) - don't have any idea :?

[boot]

That cracked top yoke is the part where the ignition barrel fixes to it isnt it? had the bike been stolen? usually trying to break the steering lock off a bike cracks this like as yours in the photo.

I bought a complete front end from USA (ebay.com) - don't have any idea :?

Is that code for 'probably'.

[Kuku]

And why do I need to use 'codes'? :rolleyes:

I saw the front end in Ebay.com - make my bid and won.
Receive it with USPS International and when I take it to pieces I saw that the top yoke is cracked.... I don't know what's the reason for this crack and no one can tell me....
Why is necessary to be stolen? It's impossible to be cracked in crash?

[yorkie_chris]

It can happen if bike falls over with the steering lock on too.

I wouldn't worry about it, too late to do anything about it now.

[Kuku]

So, to the questions...

The "GSXR-1000" K4 brake and clutch levers on "GSXR-600/750" K5 brake master cylinder and clutch support?

The "SV650" K4 rear sprocket on "GSXR-600" K5 rear sprocket carrier?

[yorkie_chris]

Look on B and c express site and see part numbers on sprocket. If they are different it probably won't fit.

[Kuku]

Different.... again :(

[yorkie_chris]

Ok you will need to play with that then.

Try put your sprocket carrier on GSXR wheel. I know curvy is nothing like GSXR600K2, but maybe you will be lucky.

If not, you need to play around. Has wheel got a tyre on it? Will it fit in the swingarm?*


*Streetfighters project SV has some problems with tyre fouling swingarm at front apparently.

[Kuku]

I already try "SV" sprocket carrier to "GSXR" wheel and it didn't fit. Also the cushions are smaller (tiny).
Wheel is without tyre and i didn't try to put it in the swingarm.
Did you mean that i must buy a new wheel? :(

[yorkie_chris]

No I mean you must try it and see if there is a problem.

What tyre does GSXR take? How wide is rim?

[Kuku]

The rim is 5,5" wide for 180/55-17 tyre.
I'll try it in the weekend...

[yorkie_chris]

Should be OK. People have put bandit 1200 wheel in which is that size.

What size is GSXR chain? 525 or 520?

[Kuku]

I think that the rear wheel should be O'k, according to the threads i read.

Original "GSXR" chain is 525 - I consider to change 525 chain and 15/45 sprockets with 520 chain and 14/47 sprockets.

[yorkie_chris]

14/47 will be very low. I had 15/47 and it was fun but a little revvy on the motorway.

[Kuku]

O'k, let it be 15/47.

In Bulgaria we have only two motorways and the condition is..... I would better say we don't have motorways :D

[yorkie_chris]

Depends what your cruising speed is really. for me cruising on my private motorway is 80mph or more.

Have a look on gearing commander to see what effect will be.

[Kuku]

Yes, mine is around 80mph (120-130kmh) too.
I already look for difference with +2 teeth on rear sprocket and think tath will be satisfying for me - I mostly ride in the city and to NONmotorway roads in weekends ;)

A few hours ago i gave the "GSXR" wheels for repair and tomorrow will take them to the paint shop :)

[Kuku]

By now I'm the proud owner of "Valter Moto" rearsets and "Gubellini" rear shock spring.

http://img692.imageshack.us/img692/8512/1pb140023.th.jpg (http://img692.imageshack.us/i/1pb140023.jpg/)http://img5.imageshack.us/img5/3097/1pb140017.th.jpg (http://img5.imageshack.us/i/1pb140017.jpg/)

I still didn't receive the spring and there are few marks on the rearsets, plus the color didn't match exactly with "black-gold" theme on the bike, but for free it's just fine ;)

[yorkie_chris]

What rate is shock spring compared to stock for that shock, and are you doing anything about the damping of shock?

[Kuku]

I don't know the spring rate at this moment. Part number is on the back position of the shock/spring and must part out the bike to see it. The bike is "CBR 900 RR" 1998 and i bought the all bike crashed for £100 :D
Tomorrow morning will parting out the rest of the bike and see what's the spring rate (keep it or sell it).


Sorry, but I can't understand "damping of shock" :?

[yorkie_chris]

Damping is the amount of resistance to movement caused by oil inside shock.

Stronger spring needs more resistance when the shock is extending (rebound damping)

[Kuku]

Yes, I know that, but can't understand the question.... what I must do with the shock damping? New oil?

I can't find the "Gubellini" spring rate - no Google, no official site, no nothing... :?
Here is the part number on it YM140167560 (http://img687.imageshack.us/img687/9648/pb150081.jpg).

[yorkie_chris]

Revalve it if you want it to work perfect, but then you need to replace nitrogen.

[Kuku]

I can't do this in Bulgaria :D
Not me, of course, but the mechanics and technicians didn't have the proper equipment.... or they have some, which is better to say they don't have :D

I measure the "Gubellini" spring and it didn't fit to "GSXR" rear shock, it's only 14,5cm., or I must use teflon sleeve :?

[Kuku]

Today I found (by the hard way) that the "SV" rear sprocker carrier and especially the rear sprocket didn't fit to "GSXR" rear wheel at all....

I also found in PazzoRacing site that the "GSXR-600/750" K4-K5 Brake lever are interchangeable with next years "GSXR", "ZX-6R" 05-06 and "Daytona 675". Clutch lever will fit from all "GSXR-600/750" 2000 to 2005 and "GSXR-1000" 2000 to 2004..... or this is only for Pazzo?! :?

[yorkie_chris]

If pazzo is same then OEM should be same too. SHOULD be, not definite :-P

[Kuku]

Hi, guys :)
I dig out the thread, because i take some parts from painting.

Frame.
http://img97.imageshack.us/img97/5153/1pc160028.th.jpg (http://img97.imageshack.us/i/1pc160028.jpg/)http://img130.imageshack.us/img130/6462/1pc160029.th.jpg (http://img130.imageshack.us/i/1pc160029.jpg/)http://img22.imageshack.us/img22/4880/1pc160022.th.jpg (http://img22.imageshack.us/i/1pc160022.jpg/)http://img97.imageshack.us/img97/365/1pc160023.th.jpg (http://img97.imageshack.us/i/1pc160023.jpg/)http://img683.imageshack.us/img683/642/1pc160027.th.jpg (http://img683.imageshack.us/i/1pc160027.jpg/)

Swingarm.
http://img130.imageshack.us/img130/7159/1pc160036.th.jpg (http://img130.imageshack.us/i/1pc160036.jpg/)
http://img683.imageshack.us/img683/1026/1pc160033.th.jpg (http://img683.imageshack.us/i/1pc160033.jpg/)

Tail.
http://img709.imageshack.us/img709/9641/1pc160040.th.jpg (http://img709.imageshack.us/i/1pc160040.jpg/)http://img191.imageshack.us/img191/5452/1pc160041.th.jpg (http://img191.imageshack.us/i/1pc160041.jpg/)

The collor is black metallic.
http://img97.imageshack.us/img97/9907/1pc160049.th.jpg (http://img97.imageshack.us/i/1pc160049.jpg/)

I also bought one "Ohlins" rear spring, which unfortunately is too short for "GSXR-600" K5 rear shock - "Ohlins" spring is 160mm. and original spring is about 190-200mm.

....and a pair of brand new "Ohlins" front springs :D
http://img683.imageshack.us/img683/893/1pb260000.jpg

[yorkie_chris]

Rate is more important than brand with spring.

What do you weigh?

Frame looks good, even if it is wrong shape ;-)

[Kuku]

93 kilograms or about 205 pounds.
I try to find out spring rate for this part number 08656-10/1476 but unsuccessfully.

[Alpinestarhero]

Kuku, looking good :D shame about the spring, can you get a refund and find the correct size spring?

[Kuku]

I bought spring from Ebay and it's difficulty to ship back and wait for refund - I'll try to sell it here next season.

[yorkie_chris]

Look on top of spring, they sometimes etch it into top. I think ideal for you would be .9kg/mm at guess.

What is stock rate in those forks?

[Kuku]

They are from Ebay too - I'll receive them after a week.... i hope :)
If they didn't match for my weight I'll sell them and buy the proper one.
I bought them because of the price (£62 delivered) - in Bulgaria pair of these cost about double.

[Kuku]

Guys,
the springs arrived extremely fast, but I still can't find out how heavy rider are they for :?
Here is the numbers on the box/springs: 08656-10/1476, 96870, 8459 :?
Thanks a lot - appreciate your help!

[Kuku]

Well, guys,
after а few emails to some "Ohlins" dealers, two days ago I receive the proper answer - springs are 10Nm, which is exactly for my weight of 95kg.
Front forks are serviced now and the springs are all-in ;)
I also find the rear sprocket carrier for free, but still don't have the fron axle to assemble the front end.
Now, the hard work is coming - fitting all front parts together and put the rear wheel on the back :D

Yesterday i get my other parts from paint job...

http://img402.imageshack.us/img402/4676/spa0199.jpghttp://img716.imageshack.us/img716/1239/spa0197.jpg
http://img190.imageshack.us/img190/8420/spa0194qx.jpghttp://img716.imageshack.us/img716/1241/spa0193.jpg

[Kuku]

Hi guys, I'm back with news :D

Yesterday and today....

Put the engine in to the frame.
http://img163.imageshack.us/img163/9804/1p2280005.th.jpg (http://img163.imageshack.us/i/1p2280005.jpg/)
http://img19.imageshack.us/img19/7784/1p2280007.th.jpg (http://img19.imageshack.us/i/1p2280007.jpg/)

And the swingarm too.
http://img709.imageshack.us/img709/1332/1p2280034.th.jpg (http://img709.imageshack.us/i/1p2280034.jpg/)

Than the crash protectors.
http://img684.imageshack.us/img684/7019/1p2280006.th.jpg (http://img684.imageshack.us/i/1p2280006.jpg/)

Assemble the front end.
http://img291.imageshack.us/img291/2075/1p2280017.th.jpg (http://img291.imageshack.us/i/1p2280017.jpg/)

And this is the end :)
http://img138.imageshack.us/img138/7032/1p2280036.th.jpg (http://img138.imageshack.us/i/1p2280036.jpg/)
http://img291.imageshack.us/img291/8994/1p2280037.th.jpg (http://img291.imageshack.us/i/1p2280037.jpg/)

For dessert is the rear shock.
http://img186.imageshack.us/img186/2646/1p2280038.th.jpg (http://img186.imageshack.us/i/1p2280038.jpg/)


Next week I must receive some other parts to continue - radiator fan and hoses for old model radiator, speedo sensor and magnet to the front sprocket, cush rubbers for rear wheel, and so on....
Until waiting this parts i must part-out and clean-up front brake calipers, and mount them on the front end with braided brake lines :D
Now, because this is not enough, I'm considering to mount the all injector system and air-box from SV1000, and to re-map the ECU for this modifications, including the new full exhaust system (I have some ideas) and K&N air filter..... but like I'm sayng - still considering this :D

[yorkie_chris]

I think SV1000 TB's are too big. Not much gain and lots more hassle compared to buying some already bored out.

[Kuku]

Yes, I read few threads about SV1000 injectors on SV650 and considering the options for bored one.
Thanks, Chris :)

[yorkie_chris]

They are USD350 from TWF

[fastdruid]

I thought the issue was more with being a bitch to fit as you need to rework all the linkages etc.
AIUI (and I'm not 100% sure I do ;) ) the reason you can use bigger TB's than carbs is you're not relying on the venturi effect to 'suck' petrol from the float bowl into the airflow. As such you cannot physically use 'too large' except that at some point you will get to the point where the TB is not the restriction, any size increase beyond that is pointless.

Druid

[yorkie_chris]

Other swap I heard about is using 749 TBs.

Problem I can see with big 'uns is low throttle will be very sensitive, and you still rely to some degree on gas velocity through the TB to mix charge.

[Kuku]

Yes.... I spoke with some friends here and I think that the bigger SV1000 TB's and ijectors will be useless on SV650.
Than the bored out throttle bodies will increase the power in high rev's which is good for track days, but not that much for road use, especially in town :?
I'll consider (pessimistically) that a little bit more....


So, parting-out....
http://img72.imageshack.us/img72/1600/1p3030002.jpg

[Alpinestarhero]

Kuku, good to see you posting on here :D your SV is looking really good :D when do you think it'll be ready?

[Kuku]

Thanks, Alpinestarhero :D
It depends on the parts which I must receive soon and the rear wheel mounting :)
I hope to ride the bike in the end of April....

[yorkie_chris]

Cool, you look to be doing a very meticulous job

[Alpinestarhero]

Thanks, Alpinestarhero :D
It depends on the parts which I must receive soon and the rear wheel mounting :)
I hope to ride the bike in the end of April....

It would be great to see a video of it, or a slideshow of it being built up :D

[Kuku]

Built up slideshow is difficult....
I make all the job mainly by my self and can't take this much photos while working with dirty hands :D
But the video in the end is absolutely compulsory!

[Kuku]

Hi, guys,
today I finally decide to do not change the injectors, air box and so....
I use my moto-parts-calculator and I found that there is more important things to spend money for. :?


Well....
I part-out and clean-up brake master cylinders.
http://img192.imageshack.us/img192/5080/1p3060003.th.jpg (http://img192.imageshack.us/i/1p3060003.jpg/)http://img6.imageshack.us/img6/2121/1p3060016.th.jpg (http://img6.imageshack.us/i/1p3060016.jpg/)

Put the front brake lines on.
http://img696.imageshack.us/img696/7567/1p3060006.th.jpg (http://img696.imageshack.us/i/1p3060006.jpg/)

Part-out and clean-up rearsets.
http://img693.imageshack.us/img693/8346/1p3060024.th.jpg (http://img693.imageshack.us/i/1p3060024.jpg/)

And put them on the frame, with new plates.
http://img11.imageshack.us/img11/1631/1p3070032.th.jpg (http://img11.imageshack.us/i/1p3070032.jpg/)http://img706.imageshack.us/img706/2158/1p3070030.th.jpg (http://img706.imageshack.us/i/1p3070030.jpg/)

I'm not sure that the photos can show you the scratches from CNC on the plates, but I decide to make them better and do some sand-paper job.... you can see the improvement....
http://img706.imageshack.us/img706/3421/1p3070039.th.jpg (http://img706.imageshack.us/i/1p3070039.jpg/)

[Kuku]

Hi guys,
there is another issue with my bike :?
I can't find top-yoke in good condition for reasonable price and decide to order the custom one.
So, the custom top-yoke will be 25mm. in thickness and there will be mounting holes for clock plates under the yoke, tap locator for clip-ons will be more comfortable and it will be look better with "SV" logo on it....
BUT is there any problems to put the ingnition key somewhere else?!
Like HERE (http://img28.imageshack.us/img28/1805/017765968.jpg), under the gas tank?
There is a lot of space, the key will not be outside of the frame, the cabel has enough lent and mounting bolt can be attached pretty easily :rolleyes:
I'll only loose the steering lock....

[fastdruid]

I'd only put it there if you can recess it enough so that you can't catch your knee on it, would be a right pain if say you turned the ign off as you entered a corner because you moved over and your trousers caught it!

I don't see any other problems apart from as you say losing the steering lock.

Druid

[Kuku]

Yes, Druid, I think over that - turning off the engine in the corner :D

The ignition must be right here, in the front of my knee.
http://img31.imageshack.us/img31/3411/14107213.jpg

This is how it's look on the bike....
http://img682.imageshack.us/img682/2413/p3120008.th.jpg (http://img682.imageshack.us/i/p3120008.jpg/)http://img194.imageshack.us/img194/5006/p3120007.th.jpg (http://img194.imageshack.us/i/p3120007.jpg/)http://img231.imageshack.us/img231/6089/p3120010.th.jpg (http://img231.imageshack.us/i/p3120010.jpg/)

From one side it must be bolt on to the overflow reservoir plate.
http://img638.imageshack.us/img638/2877/p3120012.th.jpg (http://img638.imageshack.us/i/p3120012.jpg/)http://img710.imageshack.us/img710/516/p3120011.th.jpg (http://img710.imageshack.us/i/p3120011.jpg/)

And from the other side I must use some spacer to bolt it on the radiator hose bolt.
http://img381.imageshack.us/img381/3586/p3120013.th.jpg (http://img381.imageshack.us/i/p3120013.jpg/)


Other than that, it must be funny modification :D

[Kuku]

Yesterday I order the custom top yoke - £40 with "SV" logo :D


Now move to the paint job....

Before.
http://img199.imageshack.us/img199/6986/p3130007.th.jpg (http://img199.imageshack.us/i/p3130007.jpg/)

The difference.
http://img683.imageshack.us/img683/9700/p3150011.th.jpg (http://img683.imageshack.us/i/p3150011.jpg/)
http://img171.imageshack.us/img171/599/p3150008y.th.jpg (http://img171.imageshack.us/i/p3150008y.jpg/)

After wet 600 sand-paper.
http://img210.imageshack.us/img210/984/p3150014b.th.jpg (http://img210.imageshack.us/i/p3150014b.jpg/)
http://img38.imageshack.us/img38/4162/p3150013.th.jpg (http://img38.imageshack.us/i/p3150013.jpg/)

Only the front fender is worked with 120 sand-paper first,
before wet 600, because of the stupid american painter :?
http://img301.imageshack.us/img301/4541/p3150017z.th.jpg (http://img301.imageshack.us/i/p3150017z.jpg/)
http://img696.imageshack.us/img696/740/p3150016x.th.jpg (http://img696.imageshack.us/i/p3150016x.jpg/)

[Alpinestarhero]

Having the ignition switch down there is quite cool, theifs wont look for it there if they want to hotwire the bike. What about having a steering lock though?

The other thing I'd be personally worried about is if you get caught out in a rainstorm, and the water would get there a little easier. Maybe make up some sort of deflector plate to keep the worst of the wet off?

Looking good though!

[haggis]

Ahem! Of course, it's been done before you know........ :p

http://i169.photobucket.com/albums/u220/madmud75/bike/STORRSV2.jpg

Works very well there and keeps it out of the way of spray and rain more than the standard location. the barrel is secured well and the key will not fall out so dont worry about that, and I'd say it would be really difficult to even attempt to hit it with your knee at standstill. After a few days I got used to it not being up on the yoke, fob flapping in my periforal vision.

Oh, and it confuses EVERYONE else, first time they see the top yoke or sit on the bike! I have no steering lock, but I never used it anyway so no loss.

[Alpinestarhero]

well, thats my questions answered :D

[Kuku]

This is what I've done today....

Before.
http://img185.imageshack.us/img185/8914/p3200002.th.jpg (http://img185.imageshack.us/i/p3200002.jpg/)

After first paint.
http://img339.imageshack.us/img339/5237/p3200009.th.jpg (http://img339.imageshack.us/i/p3200009.jpg/)

There is some tiny flowing but I will fix them after sand paper and second-third paint.
http://img153.imageshack.us/img153/355/p3200008.th.jpg (http://img153.imageshack.us/i/p3200008.jpg/)

Fender and tail inside.
http://img28.imageshack.us/img28/2883/p3200016.th.jpg (http://img28.imageshack.us/i/p3200016.jpg/)
http://img202.imageshack.us/img202/8515/p3200012.th.jpg (http://img202.imageshack.us/i/p3200012.jpg/)

[Kuku]

Hi guyes,
last week I receive a full set of piston and dust seals for front/rear brake calipers. I also receive a full set of brake pads :D
http://img638.imageshack.us/img638/2953/1p3290030.th.jpg (http://img638.imageshack.us/i/1p3290030.jpg/)http://img30.imageshack.us/img30/3447/1p3290031.th.jpg (http://img30.imageshack.us/i/1p3290031.jpg/)

All assemble with front brake master cylinder.
http://img89.imageshack.us/img89/8912/1p3290034.th.jpg (http://img89.imageshack.us/i/1p3290034.jpg/)http://img130.imageshack.us/img130/9318/1p3290033.th.jpg (http://img130.imageshack.us/i/1p3290033.jpg/)http://img130.imageshack.us/img130/9409/1p3290032.th.jpg (http://img130.imageshack.us/i/1p3290032.jpg/)

Because the rear brake line is from "GSXR"-kit, I still didn't figure that out :D
http://img28.imageshack.us/img28/278/1p3290035.th.jpg (http://img28.imageshack.us/i/1p3290035.jpg/)

I took my gas-tank from dyer, needs only fine grind and ready for paint.
http://img62.imageshack.us/img62/4042/1p3290024.th.jpg (http://img62.imageshack.us/i/1p3290024.jpg/)http://img189.imageshack.us/img189/7417/1p3290021.th.jpg (http://img189.imageshack.us/i/1p3290021.jpg/)
http://img18.imageshack.us/img18/8146/1p3290022.th.jpg (http://img18.imageshack.us/i/1p3290022.jpg/)http://img37.imageshack.us/img37/4507/1p3290023.th.jpg (http://img37.imageshack.us/i/1p3290023.jpg/)

[Alpinestarhero]

nice, several steps closer :smt026

[Owenski]

coming together nicely, a good project.

[Scoobs]

Haven't you finished this yet..?

Come on! Getting impatient. ;)

[Kuku]

It's almost finished, just need to clean-up :smt026

It's a joke, of course - I'm still waiting some small parts from Ebay....... 62 days.... :rolleyes:

Now I found it the SVRider, that my major problem will be the rear wheel!
It's from "GSXR-600/750" K4-K5 and it's hard to put in the SV swingarm :rolleyes:

[Kuku]

New top triple arrived :D
Just need to be anodized....

http://img413.imageshack.us/img413/8823/triple1t.th.jpg (http://img413.imageshack.us/i/triple1t.jpg/)
http://img268.imageshack.us/img268/8650/triple2.th.jpg (http://img268.imageshack.us/i/triple2.jpg/)

[williamturner1]

AWESOME thread.

Kuku (http://forums.sv650.org/member.php?u=10730) AWESOME work. Seriously wicked. 110%. Please keep posting pix and progress!

Best of luck!!

PS your matt black painted frame and parts could only make me think of:
http://entertainment.howstuffworks.com/batmobile8.htm

[Kuku]

Thanks a lot, William :D

Now the top triple is on the bike.... just for example and pictures.
I must send it (with some other parts) to anodizing.

http://img87.imageshack.us/img87/8028/1p4080013.th.jpg (http://img87.imageshack.us/i/1p4080013.jpg/)
http://img260.imageshack.us/img260/2655/1p4080017.th.jpg (http://img260.imageshack.us/i/1p4080017.jpg/)
http://img251.imageshack.us/img251/7697/1p4080023.th.jpg (http://img251.imageshack.us/i/1p4080023.jpg/)


And my Rizoma grips arrived....

http://img16.imageshack.us/img16/3623/1p4080010.th.jpg (http://img16.imageshack.us/i/1p4080010.jpg/)
http://img260.imageshack.us/img260/8521/1p4080008.th.jpg (http://img260.imageshack.us/i/1p4080008.jpg/)


There is some hard scratches, but the miller will fix them with shortening at the end..... I hope ;)

http://img195.imageshack.us/img195/7707/1p4080012.th.jpg (http://img195.imageshack.us/i/1p4080012.jpg/)

[Kuku]

Look what I've got :D

http://img717.imageshack.us/img717/8433/spa0223.th.jpg (http://img717.imageshack.us/i/spa0223.jpg/)
http://img136.imageshack.us/img136/7587/spa0229g.th.jpg (http://img136.imageshack.us/i/spa0229g.jpg/)
http://img30.imageshack.us/img30/5771/spa0228q.th.jpg (http://img30.imageshack.us/i/spa0228q.jpg/)

Just need to cut a little bit the can and mid pipe, to buy a new badge and polish/clean them (I forgot to take picture of the strap).
Later I must think about new end-straps - you can see one is bamaged :?
But for $70 ($20 price + $50 shipping), it's perfect I think :D

[Kuku]

Rizomas ready to fit :D
http://img695.imageshack.us/img695/6632/p4090005.th.jpg (http://img695.imageshack.us/i/p4090005.jpg/)

And the difference.
http://img249.imageshack.us/img249/555/1p40800121.th.jpg (http://img249.imageshack.us/i/1p40800121.jpg/)

[yorkie_chris]

Those made of alloy?

[Preston]

Omg you must have spent a masive amount of money on this !!!! Can i ask what you spent so fare>>>?

[Kuku]

Those made of alloy?Yes, it's aluminium, according to the machinist.


Omg you must have spent a masive amount of money on this !!!! Can i ask what you spent so fare>>>?
Complete front end (USA) - 350.00
Brake discs full set (China) - 142.00
Brake lines full set (UK) - 65.00
Brake calipers dust and seal kit (UK) - 65.00
"Ohlins" front forks springs (UK) - 62.00
"EBC" HH Syntered full set (UK) - 60.00
"GSXR 600-750" K4/K5 Wheels, Front fender, Rear shock (USA) - 140.00
Seat cowl (UK) - 32.00
"K&N" (USA) - 45.00
Frame crash protectors (I think these are made in China, but i purchase them from USA) - 20.00
4 LED indicators (China) - 20.00
Paint for frame, tail, swingarm, wheels, clip-ons, triples (BG) - 100.00
New custom top triple (BG) - 30.00
Rearset plates (BG) - 31.00 ("Valter Moto" rearsets are actualy free, because I bought all crashed CBR-919 for 100.00 and sell it to spares, but keep the rearsets for me.)
Wheels repair before painting (BG) - 40.00
Service for fron end (BG) - 50.00 (including seals, oil and changing front springs).
Gas tank straightening and primer (BG) - 22.00
Paint spray, sand paper, diluent and so fo painting the bike (BG) - 30.00
Rizoma grips (RO) - 27.00
"Yoshimura" end can (USA) - 44.00
Radiator from old model "SV" (UK) - 79.00.... not sure about this price :?

I'm sure that I've miss something, and that's why let me answer to your question - "About GBP 1500.00" :D
The bike cost me about GBP 2000.00, with GBP 300.00 for registration, taxes and servicing.
Besides that, I bought a lot of parts, that I can't use, because they won't fit to the bike... like "Ohlins" rear shock spring, which is too short for original "GSXR" shock :D
Or a "GSXR" rear hugger, which won't fit to the "SV" swingarm :D
In my longing for quick modifications, I make some mistakes.... and I'm selling this parts right now :D

I also must buy:
New (aluminium and welded) brackets for old model radiator - 30.00
Radiator cover - 30.00
Chain and sprockets - 100.00
Tyres - 150.00
Disc bolts - 10.00
Cush drive for rear wheel - 10.00
Of course, rear wheel swap, machining, spacers and so - max 60.00
If I can find another rear shock for "no cut the battery box" change - 100.00
Front and rear axle crash protectors - 30.00
Bar ends - 20.00
Headlight from "Yamaha MT-03" - 60.00-70.00.... I hope :?
"Ohlins" steering damper in reasonable price - 70.00
Engine oil and oil filter - 50.00
Completely new, custom made exhaust system (without end can) - max 100.00 with the help of my old friend exhaust-shop.
Some other small parts.....

TOTAL amount, in finish line, will be about a GBP 4500.00..... which is the price of the new "SV650", but mine will be some kind of unique, especially in Bulgaria, and most important - made by my self :cool:

[Rammsteinkid]

Good job mate!, just one question, how do you plan to fix the yoshi exhaust?? :cool:

[Kuku]

Thanks, Rammsteinkid ;)
I don't know yet, but will think of it when the exhaust is ready.


Today I repair the "Yoshimura", but it's not ready, because I don't have the end straps and badge.


Drill the rivets.
http://img708.imageshack.us/img708/5017/p4120019.th.jpg (http://img708.imageshack.us/i/p4120019.jpg/)

Push the rivets in.
http://img682.imageshack.us/img682/2579/p4120020.th.jpg (http://img682.imageshack.us/i/p4120020.jpg/)

Unstick the caps.
http://img94.imageshack.us/img94/4761/p4120021n.th.jpg (http://img94.imageshack.us/i/p4120021n.jpg/)

Cut the cap (bottom) from damaged side of the can.
http://img580.imageshack.us/img580/3638/p4120022.th.jpg (http://img580.imageshack.us/i/p4120022.jpg/)

Cut a little bit of outer pipe on the top, because there is tiny scratches too.
http://img138.imageshack.us/img138/3268/p41200221.th.jpg (http://img138.imageshack.us/i/p41200221.jpg/)

And pull up the outer pipe to fit the upper cap again.
http://img91.imageshack.us/img91/2008/p41200222.th.jpg (http://img91.imageshack.us/i/p41200222.jpg/)

So, the upper end is now fixed.
Cut the outer pipe of the bottom to make easy work with internal materials.
http://img156.imageshack.us/img156/6649/p4120023z.th.jpg (http://img156.imageshack.us/i/p4120023z.jpg/)

Must look like this....
http://img707.imageshack.us/img707/1651/p4120024l.th.jpg (http://img707.imageshack.us/i/p4120024l.jpg/)

Cut the wadding and wire-thing.
http://img13.imageshack.us/img13/1971/p4120025t.th.jpg (http://img13.imageshack.us/i/p4120025t.jpg/)
http://img59.imageshack.us/img59/1372/p4120026.th.jpg (http://img59.imageshack.us/i/p4120026.jpg/)

....and the internal pipe.
About 5mm. out of the outer pipe, to match the cap.
(Not nessesary 5mm. - depends on the end can cap).
http://img42.imageshack.us/img42/8619/p4120027n.th.jpg (http://img42.imageshack.us/i/p4120027n.jpg/)

Before put the cap back, must remove the internal pipe left over.
Careffuly! Don't dent the cap like I did :D
http://img695.imageshack.us/img695/8329/p4120028.th.jpg (http://img695.imageshack.us/i/p4120028.jpg/)

Remove all with thin pliers.
http://img718.imageshack.us/img718/1006/p4120029.th.jpg (http://img718.imageshack.us/i/p4120029.jpg/)

Must look like this.
http://img683.imageshack.us/img683/5535/p4120030.th.jpg (http://img683.imageshack.us/i/p4120030.jpg/)

Now putting back the cap.
http://img10.imageshack.us/img10/9941/p4120031c.th.jpg (http://img10.imageshack.us/i/p4120031c.jpg/)
http://img32.imageshack.us/img32/3958/p4120032.th.jpg (http://img32.imageshack.us/i/p4120032.jpg/)
http://img121.imageshack.us/img121/826/p4120033.th.jpg (http://img121.imageshack.us/i/p4120033.jpg/)

In :D
http://img718.imageshack.us/img718/2687/p4120034.th.jpg (http://img718.imageshack.us/i/p4120034.jpg/)

The mid pipe.
http://img265.imageshack.us/img265/9612/p4120035.th.jpg (http://img265.imageshack.us/i/p4120035.jpg/)

Must file down the moustaches.
http://img156.imageshack.us/img156/1508/p4120036.th.jpg (http://img156.imageshack.us/i/p4120036.jpg/)

And the final result :D
I hope with new straps and badge to be more beautiful.
http://img709.imageshack.us/img709/8433/p4120037.th.jpg (http://img709.imageshack.us/i/p4120037.jpg/)

I make it exactly 30cm..... an absolutely chance :mrgreen:
http://img245.imageshack.us/img245/1540/p4120038.th.jpg (http://img245.imageshack.us/i/p4120038.jpg/)


Now I have a question - can I polish/varnish this carbon fibre?
I clean it up, but nothing happens.
I don't know why (from exhaust heat or sunburnt), but you can see on the pictures that it's look like it's older than me :rolleyes:

[williamturner1]

Great work on the pipe. Wondering if this had escaped your attention.

I've never seen anything like it on an SV.

Enjoy.

Ebay UK Item No: 110518643391 (http://cgi.ebay.co.uk/SUZUKI-SV-1000-2003-STREETFIGHTER-CUSTOM-PETROL-TANK_W0QQitemZ110518643391QQcmdZViewItemQQptZUK_Mo torcycle_Parts?hash=item19bb6caabf)
http://i.ebayimg.com/13/%21Bqsrh-QBGk%7E$%28KGrHqYOKi%21Eu3T453l4BLwh6lWIqw%7E%7E_1 2.JPG

http://i.ebayimg.com/21/%21Bqs4C0wBmk%7E$%28KGrHqEH-D8EuvhH4v%218BLwiS3hkLg%7E%7E_12.JPG