My sv front end swap (RSV mille) and rebuild (loads of pics)

[barwel1992]

well after my off i managed to get hold of a rsv mille front end so hear is my log of what i have done so far :)

well this was the bike stripped down after my off all the damaged parts removed to be replaced/repaired

http://i357.photobucket.com/albums/oo16/barwell1992/P1040538.jpg

then i sorted this lot out while waiting for the forks and stuf, and sent off the sv stem to be pressed in to the rsv yoke

all panels repaired and fitted
http://i357.photobucket.com/albums/oo16/barwell1992/P1040545.jpg

My make shift head bearing tool, lol old race cut so i can hammer the new tapered race in, the cutting of the old race took ages must be hardened steal
http://i357.photobucket.com/albums/oo16/barwell1992/P1040541.jpg

new race pressed in
http://i357.photobucket.com/albums/oo16/barwell1992/P1040540.jpg

new taperd bearings in, need to get some grease though
http://i357.photobucket.com/albums/oo16/barwell1992/P1040542.jpg

tided the mess of cables up at the front, moved to behind the head stock, had to cut the air box snorkel to make sure it could breath enough with the cables there
http://i357.photobucket.com/albums/oo16/barwell1992/P1040550.jpg
http://i357.photobucket.com/albums/oo16/barwell1992/P1040553.jpg

New (to me) can, stubbied ART
http://i357.photobucket.com/albums/oo16/barwell1992/P1040549.jpg

got the brembo callipers for the new front end, they were in a right state

http://i357.photobucket.com/albums/oo16/barwell1992/P1040559.jpg

cleaned
http://i357.photobucket.com/albums/oo16/barwell1992/P1040570.jpg

and mounted up on the forks (also cleaned and polished up)
http://i357.photobucket.com/albums/oo16/barwell1992/P1040575.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040574.jpg

Rotors, these are pretty hefty and very thick compared to the sv ones (need a clean)
http://i357.photobucket.com/albums/oo16/barwell1992/P1040577.jpg


Thanks for looking

[dizzyblonde]

Keep an eye on the fuelling now you've cut the air box with the new can.
I know I have a curvy but the whole thing was dyno'd and rejetted to suit the air filter butchery and Art stubby set up(yours is much shorter than mine!).
I know things are slightly different on the pointy, but equates to the same.
TBH I reckon if it hadn't had the air filter fiddled with it would have worked perfectly fine under stock conditions...now I can't put in a standard filter as it gets really bogged down. Permanent butchered filter is the only thing she likes!

[petevtwin650]

Did you have to re-use the old piston seals in the calipers, Barwell? I've got a sticking piston on one of mine and, according to the ducati site, there are no seal kits available. Except maybe from a KTM dealer :confused:

[andrewsmith]

Did you have to re-use the old piston seals in the calipers, Barwell? I've got a sticking piston on one of mine and, according to the ducati site, there are no seal kits available. Except maybe from a KTM dealer :confused:

What year and model are calipers off?
If you've got an inkling that KTM is use the calipers (very good chance as the LC4 Prestige's use a brembo that looks v similar) you are probably right.

The importer for KTM is based in Peterborugh I think or try these who are the best on the web http://www.ktmforum.co.uk/showthread.php?8400-KTM-importer-spares/page5

[Milky Bar Kid]

Good job on those calipers! They look a million times better!

[dizzyblonde]

What year and model are calipers off?
If you've got an inkling that KTM is use the calipers (very good chance as the LC4 Prestige's use a brembo that looks v similar) you are probably right.

The importer for KTM is based in Peterborugh I think or try these who are the best on the web http://www.ktmforum.co.uk/showthread.php?8400-KTM-importer-spares/page5


same ones as from my VRaptor on first glance, so thats anywhere from 2000-2005 off top of my head.
I know the rear brakes are same as Aprillia too. Share the same master cylinder, so pretty much reckon the front to be the same.

[yorkie_chris]

Keep an eye on the fuelling now you've cut the air box with the new can.
I know I have a curvy but the whole thing was dyno'd and rejetted to suit the air filter butchery and Art stubby set up(yours is much shorter than mine!).
I know things are slightly different on the pointy, but equates to the same.
TBH I reckon if it hadn't had the air filter fiddled with it would have worked perfectly fine under stock conditions...now I can't put in a standard filter as it gets really bogged down. Permanent butchered filter is the only thing she likes!

Because main jet size has been increased to suit... pointies seem to get away with snorkel mods without having many problems.

More airflow = good anyway... snorkel is only there to keep EU muppets happy.

Share the same sh1te master cylinder,

Edited :)

[dizzyblonde]

Edited :)


:smt082
can't agree more on that one. Whats the betting that will be my next failure:smt093

[yorkie_chris]

I bet it will not be if you service it before it goes wrong.

[barwel1992]

Did you have to re-use the old piston seals in the calipers, Barwell? I've got a sticking piston on one of mine and, according to the ducati site, there are no seal kits available. Except maybe from a KTM dealer :confused:

Hi Pete mine were fine, but you can get the seals any way from KTM

4 pad caliper seals part NO: 61013019100 you need to buy X2 of them to do both sides, pistons per calliper par NO: 61013019000 need x2

2 pad calliper Seals Part NO: 58713021000 you need to buy x2 of them to do both sides, Pistons per calliper Part NO: 58713019000 need x2

get them from hear LINK (http://www.ktmspares.co.uk/)

What year and model are calipers off?
If you've got an inkling that KTM is use the calipers (very good chance as the LC4 Prestige's use a brembo that looks v similar) you are probably right.

The importer for KTM is based in Peterborugh I think or try these who are the best on the web http://www.ktmforum.co.uk/showthread.php?8400-KTM-importer-spares/page5

KTM do use the same seals (and brakes) and are the only sellers of brembo spares see above for product numbers

same ones as from my VRaptor on first glance, so thats anywhere from 2000-2005 off top of my head.
I know the rear brakes are same as Aprillia too. Share the same master cylinder, so pretty much reckon the front to be the same.

yup same as v raptor, also the same as some duc's and benelli's and obviously ktm's

[barwel1992]

ohh and the snorkel was cut about an inch so shouldn't have a big effect if any at all

[petevtwin650]

Hi Pete mine were fine, but you can get the seals any way from KTM

4 pad caliper seals part NO: 61013019100 you need to buy X2 of them to do both sides, pistons per calliper par NO: 61013019000 need x2

Nice one Barwell :cool: Is there not a seal between the two halves of the caliper?

[barwel1992]

Nice one Barwell :cool: Is there not a seal between the two halves of the caliper?

there is but i cant find the part NO listed any where, just be careful when pulling them apart and it should be ok, its just a simple o ring so if you do brake it you should be able to get one easy enough

PS watch the calliper bolts that hold the two half's together they are not hard to ruin if your not careful ohh and no idea what torque they are supposed to be, thats another thing brembo have kept from us

[barwel1992]

and back to the font end situation, ordered the pad springs 4x pad pins and one bleed nipple to the grand total of £60 ..... rip off. also ordered all the bolts i need for the front end, ordered some gold fren sinterd HH pads they were good on the sv brakes lets hope they are ok on these

[yorkie_chris]

Nice one Barwell :cool: Is there not a seal between the two halves of the caliper?

90% of time you can reuse all seals with no problems encountered.

[barwel1992]

quick update

got t599 wheel cleaned and disks mounted but the disks sit 5mm further apart than the rsv front wheel so goint to machine the calipers down a bit to make them sit further out, they are been machined down 2mm by my dads company for free so will get them back next week

still waiting on the yokes....

but hear is a mock up of how it will look

http://i357.photobucket.com/albums/oo16/barwell1992/P1040614.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040615.jpg

must get rid of that tire and stick the storm back on

[Elltg]

Wow that has a grunty look to it now. Be very interested to see how it pans out. You keeping sv lights in order to keep the body panels matching?

Also what did you use to clean your calipars they came up great!

[barwel1992]

Hi, the bikes a naked so will have new dominator lights put on and a trail tech vapor speedo with a triumph speed triple screen thing.

and the brakes took ages to get clean, started with WD40 and a rag that didnt work so then wd40 and a wire brush(soft) then wire brush and hot water, they still weren't that clean so stuck them in the dish washer after removing pistons and seals, still weren't clean enough so then go a green scouring pad and cif and that got the last of the dirt off them washed them out left to dry cleaned pistons and greased and reassembled and that was it

[xXBADGERXx]

One thing that always lets down the front end on these things is the headlights , a good set of those and they look sorted .

[barwel1992]

^ agreed, i dont really want dominator lights but i cant afford the £270 LSL urban light that i originally wanted

its the same light as i had on my old bike (OEM on that bike) but with a LSL bracket kit so i know how good it was but you cant get every thing you want lol
http://www.spieglerusa.com/UrbanHeadlight/Urban-Headlight-Page-web-images/Urban%20Headlight_opt.jpeg

[xXBADGERXx]

I scour eBay and places like that with an almost religious fervour to find things that no one else has or for something different , sometimes you come across an absolute Gem of an idea for not a lot of money .

http://cgi.ebay.co.uk/KTM-DUKE-2-HEADLIGHT-FAIRING-/220604258444?cmd=ViewItem&pt=UK_Motorcycle_Parts&hash=item335d09d88c

[Kuku]

Barwel, as you know I bought one of these good looking "MT-03" headlights and without brackets it costs about GBP 84.00 from Germany.
Total amount to UK will be about GBP 100.00 - just ask (don't worry - he speaks english) the seller of this one (http://cgi.ebay.de/ws/eBayISAPI.dll?ViewItem&item=300426730245) ;)

[barwel1992]

not sure about that light badger im looking for something smaller but the only options i like at the moment are the dominator's and the mt-03 head light hmm

and KuKu if i got it i dont know how i would mount it, thats what put me off just getting the head light and not the LSL kit :/

[xXBADGERXx]

Buy some Aluminium plate about 5mm thick and cut your own brackets out of that .

[barwel1992]

the mt light is not as simple as that, there are 4 mount points 2 are threaded and the other two use like a push in system to hold it sturdy and the holes have strange off sets as the light tapers in at the bottom i will look in to it more but its more of challenge than i can be bothered with (i want to ride my bike its driving me mad not having transport)

but i will have anther look at it and see what i come up with

[xXBADGERXx]

There`s always a way around these things , I could figure it out if I spent 5 minutes with one

[Kuku]

I think that the bottom mounting points will need some spacers between headlight and bracket, but all other parts are shown just well in the picture above and it's not that difficult to make them :)

[barwel1992]

hmm, maybe i need to see if the blokes that are doing my calipers could make something up (precision machining )

[andrewsmith]

build urself a special!! http://www.tenkateracingproducts.com/artikelen/Suzuki/964/UPPER_PART_SMALL_-_Streetfighter_S-1_-_Polyester.php

[Dave20046]

Screw the mt light buy a firebolt fairing and lights...



...off me

[metalhead19]

Screw the mt light buy a firebolt fairing and lights...



...off me

A good bit of selfless advertising ther ;)

[barwel1992]

Screw the mt light buy a firebolt fairing and lights...



...off me

lmao no ta fairings are for girls and power rangers :smt071

[metalhead19]

power rangers :smt071

I wna be the Blue one! :D

[Kuku]

Barwel, be patient - I was thinking about MT-03 brackets and till the end of the week will "invent" something, than send the measurements to the machinist that make my top yoke and see what we get :)
Fortunately, according to the top yoke price, the price for these brackets will be about GBP 20,00 and after I test it, I can send to you absolutely working measurements or a komplete kit if you wish :)
Just give me few days to measure it correctly and a week for machinist to produce it!

[barwel1992]

^ cool :D

[Jayneflakes]

Good to see your bike coming together Barwel, keep us updated with your progress. When it is finished, just be careful how you ride it... ;-)

[barwel1992]

should be getting the yoke soon and the callipers by next Wednesday :D and i will ride it like a pansy for a while :lol:

[barwel1992]

just orderd one of these with the dash surround

http://www.dirtbikebitz.com/images/products/Enduro_Computers/022-PDA_450.jpg

ordered brake lines as well hel braided tuono lines

cant decide weather to get this screen and dominator lights (the pics just showing off the screen lights dont come with the screen)
http://i222.photobucket.com/albums/dd228/koolkowlz/0002.jpg

[barwel1992]

just ordered mirrors, still need to get a light ;)

[Kuku]

Barwel, which mirrors you order? Bar end mirrors?


P.S.
I'm about a day close to make the model of the MT-03 brackets ;)
Next week monday must send it to the machinist.

[barwel1992]

bar end and they were from ebay These (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=280484980963&ssPageName=STRK:MEWNX:IT)

and cool :D

[barwel1992]

wheels are been sprayed tomorrow (powder coat) and tires refitted and balanced

[Dave20046]

lmao no ta fairings are for girls and power rangers :smt071
Pah dominator lights are for every man and his dog :razz:

Check - mate!:smt109

[barwel1992]

apart from im now not getting them ;)

so check - mate to you..

and a gixer front end is for every man and his dog .... lol

[Nobbylad]

Maybe...but not everyone crashes their bike into their Dad's car JUST as an excuse to buy more bling for their bike! lol

[barwel1992]

^ haha very funny ....

[yorkie_chris]

And some people are more fussed about performance than how bling the parts look!

[barwel1992]

^ yup and some are more fussed about how much its all going to cost, i just went with what was cheeper ....

[barwel1992]

got wheels painted :) also go the callipers back from machining but they still dont centre over the disk so need to take another 1.5mm off but i now need to take that off the forks because i cant take any more off the callipers

looks better with the black wheels now, need a bely pan next

http://i357.photobucket.com/albums/oo16/barwell1992/P1040624.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040626.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040627.jpg

down side was he put the front wheel on the wrong way round, need to get them balanced any way so will get it swapped round when i have that done

[barwel1992]

ohh and this is the main spacer, that does away with the speedo drive on the t595 wheel

http://i357.photobucket.com/albums/oo16/barwell1992/P1040628.jpg

[DarrenSV650S]

You need a black sv with a black frame :-dd

[Nelson]

Your chains a bit loose ;)

[barwel1992]

You need a black sv with a black frame :-dd

yup, shame i dont have one ;) although my tank is chipped so might get it painted some time(including the other panels), thinking matt black or just a gloss black

Your chains a bit loose ;)

haha

[xXBADGERXx]

Looking sweet there feller

[barwel1992]

^ cheers :)

[lee67]

its coming along nicely m8...and yeah black bodywork would make it look good..

[barwel1992]

yeh i agree, but spent a lot of money on it as it is, so will have to wait till later in the year before any thing gets done with the colour.

The cost so far is ridiculous but would have lost more if i had parted it out

£435 for the front end (wheel,calipers,yokes,forks,axle,disks)
£100 wheel respray (new front really needed doing)
£30 bolts (for whole front end)
£60 brembo calliper stuff
£45 brake lines
£30 wheel bearings/seals and disk bolts
£20 head race bearings
£25 brake pads
£150 trail tech vapor and dash

still need lights and a few bits and bobs, so you can see why i have no money left, although i did get £100 back from selling stuff

[chewmyr00t]

Job well done! Looks Mint!

[andrewsmith]

looks the biz barwel, but 800 quid is eye watering :smt103

[yorkie_chris]

Yeah the economy of front end swaps is negated somewhat when you smash your OEM kit to bits!

[andrewsmith]

Yeah the economy of front end swaps is negated somewhat when you smash your OEM kit to bits!

True very true

[barwel1992]

looks the biz barwel, but 800 quid is eye watering :smt103

yup :-|

Yeah the economy of front end swaps is negated somewhat when you smash your OEM kit to bits!

to right, i still have a few bits i can sell, like front wheel, calipers , master cylinder (soon) , and im trying to shift the bent front forks :P

[barwel1992]

forks have gone off to be machined, should have them back next week some time :D hopfully will have yoke's by then

[Kuku]

Up for this thread.
Barwel, I just talk with the machinist - headlight brackets will be ready next week.
I hope to send you the measurements soon ;)

[dyzio]

Don't know if this has bee asked before, but why RSV?
Was a GSXR swap too easy? ;)

[mister c]

Don't know if this has bee asked before, but why RSV?
Was a GSXR swap too easy? ;)
Tis nice to be different :)

[barwel1992]

Dyzio/mister c believe it or not it was cheaper than a gsxr front end.... at the time i could not find a gsxr front end for under £700, this lot only cost £430 (forks,yokes,wheel,axle,calipers,risers,new disks) more of a challenge but should be worth it in the end

the rest of the expense has gone on new parts for the front end like i scrapped all bolts that came with the front end, pad springs pad pins they were scrapped and replaced (the springs and pins cost £60 alone) new brake pads, new brake lines, new speedo

there has been a lot to replace.

KUKU cheers i will wait patiently for the measurements and pics

UP DATE

well its not much of a update still waiting for yoke's, and forks back from machinist's

but have pressed new bearings in to the front wheel and seals, got new disks bolts so all mounted up.
fitted new front sprocket
stripped the clutch worm drive, was a right mess

thats about all i have done right now :D

[barwel1992]

got the yokes,

:D and the brembo master cylinder off TheGr33k

http://i357.photobucket.com/albums/oo16/barwell1992/P1040653.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040654.jpg

the sv lock fits in the yoke and locks the bars just need to sort out the lock stops

just waiting for my forks back from the machinist who seems to be dragging his heals

[DarrenSV650S]

Snazzy biscuits. Get a new brake lever though

And give your cat some water

[xXBADGERXx]

And give your cat some water

Old Eagle Eyes there

[barwel1992]

lol just out of shot the cat has a dog bowl full of water :D

and im going to sand the leaver down for now, but yes will replace it ;)

ta

[Nobbylad]

Oh...and have a word with your plasterer FFS!

[barwel1992]

rolf ! its been tiled next weekend ;) and has been plastered just not skimmed as there's no point

[xXBADGERXx]

And recycle those empty Wine bottles as well ..........

[DarrenSV650S]

Oh...and have a word with your plasterer FFS!
Yeh it's looking a bit dodgy, especially around the switched spurs.
And chuck those empties out.


The sink is looking nice and clean though

[xXBADGERXx]

Poor Sod is regretting posting pics now LMAO

[barwel1992]

haha you lot are bloody picky ..

[Nobbylad]

LOL

I remember posting pics of a Gixer front end I was trying to sell....all I got on here was 'nice kitchen' !

[ThEGr33k]

lol just out of shot the cat has a dog bowl full of water :D

and im going to sand the leaver down for now, but yes will replace it ;)

ta


Yea, unfortunately that lever had worn a little. Just the damn lacquer come lose and let some water in. Sand it back and re lacquer and it should be fine I think. (and it does look worse in the photo than in person...)

Looking forward to see the finished product, especially since my bike has donated an organ :p

[barwel1992]

Yea, unfortunately that lever had worn a little. Just the damn lacquer come lose and let some water in. Sand it back and re lacquer and it should be fine I think. (and it does look worse in the photo than in person...)

Looking forward to see the finished product, especially since my bike has donated an organ :p

haha yup that's what i was going to do, will strip more of the lacquer back and make sure its proper sanded back

and yes does look worse in the pic :)

cheers, lol organ :D

[barwel1992]

:D

http://i357.photobucket.com/albums/oo16/barwell1992/P1040655.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040657.jpg

http://i357.photobucket.com/albums/oo16/barwell1992/P1040658.jpg

Had to space the ignition barrel to make the lock work, but my clock bracket will replace the washers any way when thats made, also need longer bolts
http://i357.photobucket.com/albums/oo16/barwell1992/P1040659.jpg

just a quick pic of the new can
http://i357.photobucket.com/albums/oo16/barwell1992/P1040660.jpg

bit blingy but ohh well :p
http://i357.photobucket.com/albums/oo16/barwell1992/P1040662.jpg

just need to wire in the vapor and get the light brackets and light

[rossinio]

Looks really good, the black forks are so cool I'm thinking about painting mine..

[barwel1992]

cheers :D , i do like black forks, shame the bikes not black, but i suppose i cant be picky with the price i paid lol

[Bibio]

lookin good m8ty. cant wait to see it finished.

[barwel1992]

cheers :D

going on holiday next Friday and im trying to get it done before then but not sure its going to happen

[paiste]

Looking good. Those forks look seriously chunky!

[barwel1992]

cheers

they are indeed, 53mm diameter stanchions ;)

[LewisEdge]

I'm loving this!! Keep up the good work!

[TamSV]

Good job there - looking good. My first thoughts were it would look ace with a black bike.

Do it. You know you want to.:)

[andrewsmith]

nice 1 barwel! Once it's done don't crash it.

The black looks on the fork legs, mite do mine over winter

[DarrenSV650S]

You really need to spray the bodywork black. ;)


The forks are very nice though

[Holdup]

Not my cup of tea, sorry

(Oh i dont like Darrens bike now either, must be a nekid thing)

[barwel1992]

lmao dont worry HU each to there own

thanks every one else :)

my tank needs respraying any way but not sure black would look good with the silver frame (and im not going there ...) what about grey ?

[TamSV]

What kinda grey you thinking? Maybe a nice dark gunmetal?

Definitely can't go for a bright colour with that look. It's gotta be vaguely menacing.:rambo:

Needs to be a dark colour so it can hide in doorways then jump out and get ye!

I think I need to go to bed.:)

[barwel1992]

lamo !

and yeh a dark grey or a RX8 grey

but not sure yet

[xXBADGERXx]

Bibios SV that he had at the GMII last year was a nice colour , the official grey one , looked very "Pimpy" with the front end conversion .

[Dave20046]

if you do want to get it professionally sprayed grey I have a tin of mercedes grey for sale

[Holdup]

lmao dont worry HU each to there own

my tank needs respraying any way but not sure black would look good with the silver frame (and im not going there ...) what about grey ?

Indeedy, just how i think that black with a silver frame works perfectly :p there was a all black SV with lower seat cowl etc etc and silver frame for sale on here a while black, i thought it was stunning

[barwel1992]

Bibios SV that he had at the GMII last year was a nice colour , the official grey one , looked very "Pimpy" with the front end conversion .

i think i saw that one on hear, it did look rather nice

if you do want to get it professionally sprayed grey I have a tin of mercedes grey for sale

the spray job will have to wait a while (Christmas time) because of funds (still need a new jacket ) but it might take you up on it closer to the time

Indeedy, just how i think that black with a silver frame works perfectly :p there was a all black SV with lower seat cowl etc etc and silver frame for sale on here a while black, i thought it was stunning

hmm i suppose with a black belly pan as well it could look good

[barwel1992]

ohh why ohh why did i buy 4mm steel for the clock bracket lol, its going to be a pain in the bloody ass to cut with a dremel