Winter work

[DarrenSV650S]

I always enjoy reading rebuild type threads so I thought I'd stick one up showing what I'm up to this winter. As some will know my crankshaft snapped last month so the bike has been stripped down ready for the engine drop.

http://i88.photobucket.com/albums/k164/DarrenStewartTait/02946f97.jpg

While I'm waiting for that I have started to clean up the crusty oil cooler for painting. Sanding is lots of fun :(

http://i88.photobucket.com/albums/k164/DarrenStewartTait/fdc1a8b5.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/fa0f1cee.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/e3cb093f.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/180a2647.jpg

Just left the calipers to soak until I get a piston puller. They will either get painted or powdercoated because the paint is looking a bit rough. The torx bolts are a bit rusty, not sure if I'll replace them or just clean them up.

http://i88.photobucket.com/albums/k164/DarrenStewartTait/45d7fab7.jpg

I'm also thinking about having the frame powdercoated black while it's all stripped down and spraying the fairings orange. But this is more a dream really because I don't have the money for all that

How it would look
http://i88.photobucket.com/albums/k164/DarrenStewartTait/fd859c3f.jpg

[maviczap]

To raise funds for your rebuild don't forget that Curvy owners will be looking for pointy exhaust cams to fit for a good cheap performance upgrade, thats if you've got a complete engine to do the swap?

[Wideboy]

i like the orange and black do it, a stubbied hilevel would finish that off i reckon

[squirrel_hunter]

Different. I like it.

Those headlights, whats the story there?

[ImplodedHamster]

wow, that looks very nice. and for once: leave the can at that length. it wouldn't look right stubbied

[andrewsmith]

Darren part out the old motor.

That'll pay for the frame powedercoat and most of the respray.

[Binky]

Definitely do the orange/black frame change. Looks the t!ts! :)

[Dave20046]

Paint scheme looks the mutt's vagina , lights aren't to my taste but bo bum.

What lights did you have previously? dominator styley?

[DJ123]

***Off Topic***
Where did you get your exhaust hanger from???

[DarrenSV650S]

To raise funds for your rebuild don't forget that Curvy owners will be looking for pointy exhaust cams to fit for a good cheap performance upgrade, thats if you've got a complete engine to do the swap?
Yeh I will be breaking my engine, but whatever I make from that will pay towards the new engine

i like the orange and black do it, a stubbied hilevel would finish that off i reckon
hmm not keen on high levels on pointys. The stubby I had before was too loud for me

Different. I like it.

Those headlights, whats the story there?
lol not a fan then? They are halogen projectors

Paint scheme looks the mutt's vagina , lights aren't to my taste but bo bum.

What lights did you have previously? dominator styley?
Had dominators, then hid's which were naff, now these

***Off Topic***
Where did you get your exhaust hanger from???
It's a harris hanger. Can't remember where I got it, had it years. Might have been someone off here



Anyone got any tips for painting the cooler? I usually seem to mess up painting

[squirrel_hunter]

Different. I like it.

Those headlights, whats the story there?

lol not a fan then? They are halogen projectors



Don't know. Personally the chrome is not a good look with the black and orange. The shape however I think does match. So who made them and that?

[pookie]

I like where you're going with it..I'm a bit partial to the orange colour too.. looking forward to sv tango mk2

[DarrenSV650S]

Don't know. Personally the chrome is not a good look with the black and orange. The shape however I think does match. So who made them and that?

I know, I've been thinking about the chrome/black thing. There's also both the silver yokes. Could get expensive.

It's a secret :-$

[squirrel_hunter]

I know, I've been thinking about the chrome/black thing. There's also both the silver yokes. Could get expensive.

This is something I've thought about, after powder coating the frame where do you stop? But if there was more chrome on the bike against the black frame then i don't think it would be as obvious. The sliver on the yokes etc is more subtle so I think it would be fine without. However powder coating isn't as expensive as painting...

It's a secret :-$

Don't worry, no ones listening...

[DarrenSV650S]

There would still be the lights, yokes, exhaust hanger, rad guards, pegs/hangers, engine obv would still be silver. It could work

[DarrenSV650S]

Got my piston remover today. It does scratch the inside of the pot a little, but better than scratching the outside

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0086-1.jpg

Before
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0076.jpg

Caliper cheese
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0081.jpg

Stripped
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0080-1.jpg

Cleaned
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0084-2.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0085-1.jpg


I'm going to get the rear powdercoated gold too. The little bolt cover wouldn't budge though so had to drill it out, then just unscrewed the bolt underneath. I'll just have to bung it with something when I rebuild it

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0088.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0089-1.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0090-1.jpg

[Lozzo]

How it would look
http://i88.photobucket.com/albums/k164/DarrenStewartTait/fd859c3f.jpg

That would look great in Kawasaki Candy Burnt Orange

[DarrenSV650S]

That would look great in Kawasaki Candy Burnt Orange

Like this?
http://i88.photobucket.com/albums/k164/DarrenStewartTait/564abd32.jpg

That is a nice colour. I was thinking focus st orange maybe. They both look good

http://i88.photobucket.com/albums/k164/DarrenStewartTait/ad5d963e.jpg

[DarrenSV650S]

Calipers are away getting powdercoated gold :D

Got the engine today from ImplodedHamster :smt023 Just have to swap over some of my casings
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0094.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0095.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0097.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0098.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0099.jpg

I got a cheap halfords trolley jack and have just started undoing the bolts as per the haynes.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0100.jpg

How do I get this spacer out though? It doesn't seem to have a normal socket shape on it.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0106.jpg

[Berlin]

Thats the one you need a 6 sided socket for. I'm not sure which one that is but I belive I used a 7/16ths on that one as that was all I had to fit in 6 sided. The others are 19mm 6 sided sockets.

The 12 sided ones don't fit.

http://www.timesert.com/images/kits/drainplug/12point.jpg


If you're really stuck and can't find one, get a reall good grip with some mole grips *straight off* the nut *on the flats* and put a turning bar through the mole grips.
C

[squirrel_hunter]

Got the engine today from ImplodedHamster :smt023 Just have to swap over some of my casings

So whats the plan with the engine?

[Specialone]

Hex = 6 sides
Bi hex =12 sides.

Now I can't see any flats on that pic so am I missing something? How does a hex socket fit on that?

[DarrenSV650S]

Oh right cheers berlin.

So whats the plan with the engine?
My old engine? Check the heads are ok and sell them

[Berlin]

There are flats on it but no corners on those there flats, hence the need for a hex socket (or, if you're really fancy, 6WD sockets, which are fabtabulous!)

C

[squirrel_hunter]

I mean are you swapping this other engine in and replacing the covers or taking the crank from that to go in yours?

[DarrenSV650S]

Hex = 6 sides
Bi hex =12 sides.

Now I can't see any flats on that pic so am I missing something? How does a hex socket fit on that?

It does have some sides but they dont look flat to me? Ill try get a better pic of the loose one i managed to get out by hand later tonight

[DarrenSV650S]

These replies are coming too fast for my tapatalk with crap signal to keep up lol.

Im using the new complete engine with my old covers on it

[Berlin]

Just been out and measured it and if its the same one I'm thinking its 23mm across the flats. and it was a 7/8ths socket I used. But it was an old socket and might have been stretched.

There's not much torque on there so you should be able to back it out two turns with mole grips, which is all you need.

C

[Bibio]

Daz, common wheel nut wrench sizes are 23,21,17 and 19mm 6 sided and most 'spider' type have all 4 sizes on them. or i can pop 2 double ended sockets in the post with the 4 sizes above if you like.

[DarrenSV650S]

Just been out and measured it and if its the same one I'm thinking its 23mm across the flats. and it was a 7/8ths socket I used. But it was an old socket and might have been stretched.

There's not much torque on there so you should be able to back it out two turns with mole grips, which is all you need.

C
I tried all my metric and imperial sockets but none gripped it. Tried grips but it was starting to damage it. Do you have to toque it up when it is put back in?


Daz, common wheel nut wrench sizes are 23,21,17 and 19mm 6 sided and most 'spider' type have all 4 sizes on them. or i can pop 2 double ended sockets in the post with the 4 sizes above if you like.

Are wheel nuts the same shape?


Got this pic of the one that was loose. It's got 6 of these curved sides
http://i88.photobucket.com/albums/k164/DarrenStewartTait/acd7faf3.jpg

[Bibio]

surface drive/ribe fitting.

[Berlin]

Perfect excuse to buy yourself a set of Metrinch 6WD sockethttp://www.metrinch-tools.com/website/produkten.php?subnr=7s!

Every mechanic should have some! You'll never round a nut or bolt off again!
(Mine are called Surface drive and made by a company called Franklin and are cheaper than Metrinch but only go up to 13mm, You can get them bigger though)

Xmas is coming too ;-)

[DarrenSV650S]

Someone must have put these in my toolkit last night because I swear they weren't there yesterday :-k

http://i88.photobucket.com/albums/k164/DarrenStewartTait/0d5b1c40.jpg

Idiot proofed all the bolts and stuff
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0109-1.jpg

And it's out! :D Who said you need a hand to get the engine out. Although getting the new one in might be a different story...
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0111.jpg

It's a proper naked now
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0110.jpg

[TamSV]

Nice one Darren.

Did your engine drop include the almost compulsory test of tensile strength of a random cable/hose that you forgot to disconnect? :)

[DarrenSV650S]

No lol I double checked all the spacers and cables were out the way and had the two engine cables taped up out the way :D

I did make use of a near by bungee to hold the front cylinder up a bit while I lowered it though

[Berlin]

Looking good! You should have that running again tonight then! :-)

[andrewsmith]

Looking good! You should have that running again tonight then! :-)

lol

get cracking you'd be done before you know it

[Jayneflakes]

It's a proper naked now
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0110.jpg

Strangely beautiful and yet so wrong, frame minus engine is a sad sight. Have you considered fitting a set of mountain bike gears just so you can still ride around while you sort the engine out! :grin:

[DarrenSV650S]

Looking good! You should have that running again tonight then! :-)
lol not much chance of that. Gonna give the frame and engine a good clean while it's out

Strangely beautiful and yet so wrong, frame minus engine is a sad sight. Have you considered fitting a set of mountain bike gears just so you can still ride around while you sort the engine out! :grin:
oooh that sounds like fun lol. It's a lot easier to move about the garage just now anyway :)

[Holdup]

Idiot proofed all the bolts and stuff
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0109-1.jpg



Are they Darren proofed though?

[DarrenSV650S]

Darren proof falls under the Idiot proof bracket. If you want them Holdup proof I'd have to get crayons and hand puppets involved

[andrewsmith]

Whats WB proof then

[DarrenSV650S]

I don't know if that's even possible?

[Ed]

I wish I had the skill to do something like this.

I'm hugely enjoying this thread Darren:thumright::thumright:

[DarrenSV650S]

Cheers Ed. Don't really have any skill though, just following the haynes and seeing what happens lol

[DarrenSV650S]

Swapped over the alternator cover. The gasket looks fine so I was thinking about just leaving it? Although just had a look on wemoto and it's only £8.40 so might just change it anyway.

The clutch cover just peeled apart so I've been scrapping the rest of it off with a stanley blade. So I'll be ordering one of them anyway. Are wemoto gaskets ok?


I need to swap over my old head cover seal to fix this
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0097.jpg

Am I going to be able to take it off without breaking it and what glue do you use to put it back on?

[muzikill]

Well done so far, it's a pity youve posted in the photos section for this swap over as i missed it up to this point. As long as the gaskets look fine without any damage you should be ok. Remember, you seal part of the cover using liquid gasket!. I used the old ones during the rebuild as they were fine. But i didnt replace the gasket covers so the rubber gasket matched the seal in between already . Dont chuck any spare ones away, they will come in handy if you need to remove the covers in the future to do a gap check and you need to replace them for any reason.

If the gaskets baked/stuck on watch what your doing with that stanley blade.
I used these...........
http://www.ebay.co.uk/itm/CARPLAN-GET-YER-GAS-KIT-OFF-400ML-/110724221174?pt=UK_Car_Accessories_Car_Care_Cleani ng&hash=item19c7ad88f6
http://www.ebay.co.uk/itm/NEW-5-PC-GASKET-SCRAPER-AND-REMOVER-SET-SILVERLINE-/120628545964?pt=UK_Hand_Tools_Equipment&hash=item1c160589ac

Made the job so much easier with no worries and left the surfaces spotless for the new gasket and minimise any scratch worries for leaks.

Im going to overhaul the sv brakes soon, the tool for removing the pistons? - how much & where from?


just thought, ive got the tools for gasket removal youve got the tools for removing the brake pistons if we get stuck swop? - save ourselves money?

[TamSV]

Swapped over the alternator cover. The gasket looks fine so I was thinking about just leaving it? Although just had a look on wemoto and it's only £8.40 so might just change it anyway.

The new gasket only seals one joint though. A tube of Universal Blue is less than a fiver and you'll be bodging gaskets for years. :-dd

The clutch cover just peeled apart so I've been scrapping the rest of it off with a stanley blade. So I'll be ordering one of them anyway. Are wemoto gaskets ok?

I've got one on my SV clutch cover and it's not leaked. YMMV of course. It's worth a go if it's a lot cheaper. The worst that can happen is it'll leak a bit. I'd use OEM for head gaskets and stuff where the consequences are more serious.

I used that Get Yer Gasket Off stuff and it was OK. You'll get a wee buzz on though if you're not careful. Open the window and, if Jimi Hendrix hands you a spanner, it's time to take a break. :p

I need to swap over my old head cover seal to fix this

Am I going to be able to take it off without breaking it and what glue do you use to put it back on?

Tap round the valve cover with a rubber mallet then lift the cover off gently. The rubber gasket will probably be stuck in the semi-circles on the head. Gently wiggle it off - don't prise it with anything.

I had these off on both my SV's to do the clearances. The first one had gasket sealant but only in the semi-circles (this is as per the manual). I cleaned it all off and refitted with some Loctite black sealant on those areas. I can't remember the product number but I can check if you want it.

The second SV didn't have any sealant anywhere on the gasket. I reassembled without using any and it was absolutely fine.

[muzikill]

Yeah that 'gasket off' stuff has to have the most potent vapour ever. I was scared to turn the garage light switch off in case the whole place ignited.

Im chuffed with the ecosse diy bike efforts this year. When i was doing my rebuild i thought it was only going to be me attempting this stuff at this end of the country. At least we know now theres a few of us to lend a hand if needs be.

[DarrenSV650S]

Damn why didn't I read this earlier!
The internet isn't working just now so I'm just using my phone and must have missed this.

Well done so far, it's a pity youve posted in the photos section for this swap over as i missed it up to this point. As long as the gaskets look fine without any damage you should be ok. Remember, you seal part of the cover using liquid gasket!. I used the old ones during the rebuild as they were fine. But i didnt replace the gasket covers so the rubber gasket matched the seal in between already . Dont chuck any spare ones away, they will come in handy if you need to remove the covers in the future to do a gap check and you need to replace them for any reason.

If the gaskets baked/stuck on watch what your doing with that stanley blade.
I used these...........
http://www.ebay.co.uk/itm/CARPLAN-GET-YER-GAS-KIT-OFF-400ML-/110724221174?pt=UK_Car_Accessories_Car_Care_Cleani ng&hash=item19c7ad88f6
http://www.ebay.co.uk/itm/NEW-5-PC-GASKET-SCRAPER-AND-REMOVER-SET-SILVERLINE-/120628545964?pt=UK_Hand_Tools_Equipment&hash=item1c160589ac

Made the job so much easier with no worries and left the surfaces spotless for the new gasket and minimise any scratch worries for leaks.

Im going to overhaul the sv brakes soon, the tool for removing the pistons? - how much & where from?


just thought, ive got the tools for gasket removal youve got the tools for removing the brake pistons if we get stuck swop? - save ourselves money?
I've replaced both engine gaskets now. I used a stanley blade and light sand paper. Hope it isn't damaged. Can't see your ebay link but it probably would have come in handy. You're welcome to a shot of the piston removers if you want. They do mark the pistons a little but I don't think the inside of the piston matters too much does it


The new gasket only seals one joint though. A tube of Universal Blue is less than a fiver and you'll be bodging gaskets for years. :-dd



I've got one on my SV clutch cover and it's not leaked. YMMV of course. It's worth a go if it's a lot cheaper. The worst that can happen is it'll leak a bit. I'd use OEM for head gaskets and stuff where the consequences are more serious.

I used that Get Yer Gasket Off stuff and it was OK. You'll get a wee buzz on though if you're not careful. Open the window and, if Jimi Hendrix hands you a spanner, it's time to take a break. :p



Tap round the valve cover with a rubber mallet then lift the cover off gently. The rubber gasket will probably be stuck in the semi-circles on the head. Gently wiggle it off - don't prise it with anything.

I had these off on both my SV's to do the clearances. The first one had gasket sealant but only in the semi-circles (this is as per the manual). I cleaned it all off and refitted with some Loctite black sealant on those areas. I can't remember the product number but I can check if you want it.

The second SV didn't have any sealant anywhere on the gasket. I reassembled without using any and it was absolutely fine.

I tried taking off the rocker cover seal but it was just going to rip so I've got a new one now. The damaged seal from the new engine wasn't glued. Might glue this one in though. The suzuki dealer said some people use a few drops of superglue






I've got my calipers back from Triple S and they look brilliant! Got some pics but can't upload them till our internet is fixed.
Really need to hurry up and get the oil cooler sprayed before it gets too cold!

[TamSV]

I don't get how a couple of drops of superglue is going to help that gasket seal. Surely all it does is mean you'll never again be able to remove the gasket without damage. :scratch:

[DarrenSV650S]

Hmm yeh. I might just try it without glue.

[svian]

Whenever I have trouble with a gasket staying in place I use a very thin smear of grase on it which holds it in place no problem (paper or rubber gaskets). And it often makes removing the gasket at a later date easier too.

[DarrenSV650S]

Bling bling! :D
http://i88.photobucket.com/albums/k164/DarrenStewartTait/21eadc88.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/5a78eee6.jpg

All greased up ready for new pads
http://i88.photobucket.com/albums/k164/DarrenStewartTait/7795cc9c.jpg

[andrewsmith]

Nice!

What did that cost you Darren?

[DarrenSV650S]

£100 :(

Bit more than I was expecting to be honest but the finish is perfect. No overlap or anything

[andrewsmith]

£100 is nothing TBH as that will take an age to crack and fail

[muzikill]

Can you share the knowledge on the following?
Paint used for the cooler.
Grease used for the brake pistons.
How much to get the brakes powder coated coz i wanted to do my own.
What you had to replace when overhauling the brakes. Where you got the parts from and how much.

Is there anything i should do before removing the brakes from the stock lines that would be easier to do in situ?

[Richie]

Calipers Look the F..ing Don... :0)

[DarrenSV650S]

£100 is nothing TBH as that will take an age to crack and fail
True

Can you share the knowledge on the following?
Paint used for the cooler.
Grease used for the brake pistons.
How much to get the brakes powder coated coz i wanted to do my own.
What you had to replace when overhauling the brakes. Where you got the parts from and how much.

Is there anything i should do before removing the brakes from the stock lines that would be easier to do in situ?
I've got this paint, haven't used it yet though
http://www.frost.co.uk/automotive-paint/eastwood-radiator-gloss-black-aerosol-340g.html
Red rubber grease for the pistons
Calipers were £100 for the 3 including postage back
Just had to replace the caliper seals. I got a seal kit from wemoto because it is half the price of oem seals. Has everything you need including a little grease. Not a lot though but I have my own tub

You could pump the pistons out with the calipers still attached. Would mean you don't need the piston tool. I never had much luck doing it that way and it made a bit of a mess so don't try now.
Calipers Look the F..ing Don... :0)
:cool:

[Holdup]

mmm now i want to get my calipers painted gold and my rear one repainted

[Specialone]

Bling bling! :D
http://i88.photobucket.com/albums/k164/DarrenStewartTait/21eadc88.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/5a78eee6.jpg

All greased up ready for new pads
http://i88.photobucket.com/albums/k164/DarrenStewartTait/7795cc9c.jpg

They look very niiiiice :)

£100? Bargain IMO

[muzikill]

Nice paint job. Gawd im jealous. I wonder if i could do a diy job and paint mine now.

[Ed]

I'm in awe, as i woulodn't dare touch my brakes.

[DarrenSV650S]

Plugged up the rear caliper's pin with an old bleed nipple cover :p
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0122.jpg

I was planning to replace the front pads, but they do have a little life in them so they'll do just now
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0124.jpg

Fitted
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0127-1.jpg

Might change these stainless bolts back to standard.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0133.jpg

They match the forks and shock reservoir really well :D
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0132.jpg

Thought it was about time I sprayed the oil cooler. The last time I sprayed in the garage I got paint specs on everything. So I set up a little tipi paint booth :lol:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0125-1.jpg

Using this nice healthy paint
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0134-1.jpg

Came out pretty good
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0136.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0137.jpg

I also removed all the old water pipes and cables that I wont need from the new engine. Took out the old exhaust gaskets and cleaned up the ports.

New and old. Which type is best? :)
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0135.jpg

Just need to give the engine and frame a good clean and it will be ready to go back in. When I was having a look at what I'll have to clean I noticed a gap between the swingarm and the frame. And if I move the swingarm the gap closes up :eek:

Is this the "designed swingarm freeplay" built in by suzuki? Or do I need to tighten it up?
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0129-1.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0131.jpg

[DavieSV]

That was the exact case with mine.
You carn't "tighten" the play out of it, because it is just trying to squash the spacer tube.
You could machine the inner tube down to regain the required play, but if you take too much off your knackered.
I made some shims for mine, so that I could shim it and reassemble it to check play and then adjust as required, it worked a treat and handled like a completly different bike after :)
See here. (http://forums.sv650.org/showthread.php?t=145453)
I made extra shims ;)
PM Barwel1992 (http://forums.sv650.org/member.php?u=11837), although I don't think he has been on for a while. He had all the shims to take the play out of his, he said he would pass on the ones he didn't use, to anyone who would need them.

If you want to shim it, but carn't get hold of the shims from Barwel, I could make some more up, but I'm up to me crackers in it at the moment but should be able to squeeze them in some where, I haven't got the dimensions any more though, so would need to know the outside and inside dimensions.

Hope you get it sorted.

[DarrenSV650S]

Cheers Davie, I'll give barwel a shout. Hopefully this will fix the headshakes I've been getting

[DarrenSV650S]

Finally got on with the engine today. I ratcheted it up to the frame then got the trolley jack underneath

http://i88.photobucket.com/albums/k164/DarrenStewartTait/8a22d0c3.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/7a9802cf.jpg

Went pretty smoothly actually. Got all the bolts hand tight until I get my new torque wrench.

Got to this last bolt and it didn't feel right trying to tighten it. Took it out and it is slightly bent :confused: How would that happen?
http://i88.photobucket.com/albums/k164/DarrenStewartTait/d5e83552.jpg

[muzikill]

The only thing I think is all the weights been on it. You didnt leave all the weight on one bolt?

Wont be hard to straighten it. Big heavy hammer and a flat surface. Now you know how gash those bolts are. I see the furry appearance of yours was exactly the same as mine.

[andrewsmith]

The only thing I think is all the weights been on it. You didnt leave all the weight on one bolt?

That is all I can think of.
Darren that bolt is the first one that goes in as it aligns the motor up properly.

You binned it in the past?

[muzikill]

Ehhh... You are going to clean the bolts up arent you?

[DarrenSV650S]

The only thing I think is all the weights been on it. You didnt leave all the weight on one bolt?

Wont be hard to straighten it. Big heavy hammer and a flat surface. Now you know how gash those bolts are. I see the furry appearance of yours was exactly the same as mine.
No I didn't leave the weight on it. Think I might just get a new one

That is all I can think of.
Darren that bolt is the first one that goes in as it aligns the motor up properly.

You binned it in the past?
It's not the first according to the haynes. Yeh it has been down the road but nothing serious


Ehhh... You are going to clean the bolts up arent you?
emmm no lol

[muzikill]

Dont see why you cant hammer back into shape rub it down a bit and re-use it. Save you pennies on a overpriced OEM.

[DarrenSV650S]

Yeh I could but gonna see how much it is anyway. Just wish the posty would hurry up so I can get on with bolting it all up

[DarrenSV650S]

Bling :p
http://i88.photobucket.com/albums/k164/DarrenStewartTait/2b5ccc6e.jpg

Got it last week and got everything torqued up. I straightened the bent bolt a little and jiggled the engine a bit and it went in ok.

Gave Hein gericke's optiglanz a try on the pipes. Left it on for like 20 minutes. Cleaned it a little but not brilliant.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/ec9d0a35.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/5fed0e90.jpg

I was going to put some more on but I got the washers for the oil cooler last night, so I was dying to get the oil and coolant in and start it up. So put the exhaust on quick and filled everything up. Battery in. Excited as hell. Pushed the button and the solenoid clicked, the dash went dim, and the starter didn't move. :smt107 whaaaaaaaaaaaaat!?

Tested fuses, voltages, connections etc. Eventually gave up, very confused and gutted I couldn't get it running.

So tonight I took the starter out, bolted it to the casing and tried it. It was a bit jittery to begin with sounding like it was drawing too much current, then it just spun up fine. So I'm thinking it was maybe a little seized?

Stuck it back in and it started up fine, and sounded worryingly rattly. Then I remembered I hadn't bothered putting the front exhaust gasket in, thinking I would be taking it off again for cleaning. But decided I couldn't be arsed cleaning it again so put the gasket in and let it run for a bit to get the coolant and oil levels sorted. Happy days :D
Rode up and down the garage a few times, nearly crashing in to the cupboard cos the front brakes aren't bled yet :lol:

So this is how it stands now. Still need to give the engine a good clean, then see about fitting the swingarm spacers to sort the slop. Got to get the front sprocket off somehow, it's tight as hell. Could do with a windy gun for that. Then I'm thinking of trying new sprocket sizes for better acceleration.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/3c9df45c.jpg

[andrewsmith]

Looking good Darren

I love the bling bling wrench. Got mine before Christmas hardly touched it

[TamSV]

Good work. :cool:

Nothing like the feeling when they start up. Especially when you've just experienced the feeling you get when they don't. :p

[Jayneflakes]

Well done Darren, that looks really nice. :D

[DarrenSV650S]

Haven't been very motivated lately, but I could do with the bike for work just now. So I'm trying to get a chain and sprocket ordered just now. I'm going to go for a 47 tooth rear sprocket :p
I can't get the front sprocket off though, and I don't have a chain tool. So I'm gonna fit the new chain with a clip link and then get the garage to swap the front sprocket and rivet the link.

I started taking off the swingarm tonight.

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0159.jpg

It's quite tricky getting the exhaust out with a shock reservoir in the way! I might have scratched that a little :( and I might have completely mullered the exhaust gasket between the front downpipe and the mid section #-o

I'll see tomorrow how big a shim it will need. I noticed the dogbones move side to side, is that supposed to happen? :?
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0160.jpg

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0161.jpg

[andrewsmith]

Darren

Its getting there. Where you get the chain clip link from? I'm going to do the same save keep lubing a kaput chain

[DarrenSV650S]

Shirlaws in aberdeen. Should be able to get them from any DID dealer. I'm gonna see tomorrow if they can get me that exhaust gasket too

[andrewsmith]

cheers Darren

Going to get one tomorrow sometime

[DarrenSV650S]

Upskirt shot :smt047
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0163-1.jpg

Gonna order a new guide. Suzuki want £27 though :eek:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0165-2.jpg

I was expecting this to be dry aftr 40k miles but there's plenty of grease :o
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0166-1.jpg

Mingin...
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0167-1.jpg

Blingin :cool:
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0168-1.jpg

Slightly chewed though
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0169-1.jpg

Got various sized shims from barwel, which were made by DavieSV. (Davies thread (http://forums.sv650.org/showthread.php?t=145453))

First I tried two 0.5mm shims, one either side. Torqued it up but the arm was a little sticky to move. It still dropped down when I let go but didn't feel free.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0170-2.jpg

So then I tried one 0.5mm and one 0.4mm

This is the original gap with no shims
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0171-2.jpg

And this is with the 0.5 and 0.4
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0172.jpg

Couldn't see the gap once I torqued it up. It is nearly perfect. I can still feel it hitting each side when I move it, but it isn't travelling far at all. I think a 0.45mm shim would be just about perfect. Not sure if it's worth it or not

[DarrenSV650S]

DavieSV very kindly made me up a 0.45mm shim :thumbsup:

And he made some extra ones so if you are fixing your swingarm let me know and I'll post them on.
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0181.jpg

New exhaust gasket
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0176.jpg

Got a new chain guide fitted
http://i88.photobucket.com/albums/k164/DarrenStewartTait/e0398412.jpg

and a new chain and 47 tooth sprocket :cool:
Which needs 110 links on a SV650S btw, not 114 as this site tells you www.sprocketcalculator.com
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0175-1.jpg

44/47
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0177-1.jpg

Fitted
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0178-1.jpg

Spring clip fitted until I can get it to the bike shop and get them to rivit it and swap the front sprocket. Wasn't as easy to fit as I thought it would be. Takes a bit of effort to push the sideplate on
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0179-1.jpg

And it is finished :D :D :D
Just need to tax it next week and get the chain done
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0180.jpg

[Richie]

Nearly had to tell some one off then....
but then read the caption.....

http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0179-1.jpg

Yes please don't ride it until it been Riveted :0)

and why is a red bucket fitted? =0)
http://i88.photobucket.com/albums/k164/DarrenStewartTait/DSCF0180.jpg

[DarrenSV650S]

I'll have to ride it about 25 miles to get it riveted. The bucket is a diy topbox :p

[andrewsmith]

Nice!!
Mines getting the same chain treatment to get the 5 miles

[Dave20046]

Looking smart dazzla, I'm well tempted by an unnecessary spend on some new gsxr forks just for radial calipers. It stop well?
DavieSV very kindly made me up a 0.45mm shim :thumbsup:

And he made some extra ones so if you are fixing your swingarm let me know and I'll post them on.


Potential dibs?

[maviczap]

yep looking good

[DarrenSV650S]

Looking smart dazzla, I'm well tempted by an unnecessary spend on some new gsxr forks just for radial calipers. It stop well?


Potential dibs?
Yeh the brakes are ace. PM me your addy if you decide to do it

yep looking good

Cheers :)

[Bibio]

nice one Daz. glad to hear your back on the road, you should give yourself a pat on the back m8. you done a splendid job.

[DarrenSV650S]

Cheers bib :)

[Dave20046]

How did you keep the bike up when doing the swing arm darren? I can see an abba stand in shot, assuming you used that.
Would it be massively difficult to do with just a trolley jack and maybe some rope?

[Bibio]

Dave. a cppl cheep axle stands and turn the foot pegs round then place axle stands under foot pegs.

[DarrenSV650S]

I've got the abba adaptors that use the footpeg bolts instead of the swingarm mounts. I guess you could take the seat off and put a strap through the frame up to the roof. If you have an abba stand you can have a shot of my adaptors if you want

[Dave20046]

Cheers guys, I don't have an abba stand so think I'll just have a pop with the jack and axle stands (and probably rope too!) and see how I get on.

[andrewsmith]

Cheers guys, I don't have an abba stand so think I'll just have a pop with the jack and axle stands (and probably rope too!) and see how I get on.

There is an engine winch somewhere in Yorkshire, Lancs, Preston