HOW-TO De-restrict SV650 carb bikes with Suzuki kit

[TSM]

I am going to best explain how i have de-restricted my bike which was fitted with a genuine Suzuki restriction kit.

WARNING - This is only for people that hold an unrestricted licence, if not you will be breaking the law.

Also this has been done to the best of my knowledge, whatever you do to your bike is your responsibility and if you are in any doubt with these instructions do not carry out the procedure.
PS. To the gurus, if there is any gaping problems with this please tell me so i can ammend the instructions.

Step 1 - Airbox removal
Remove front seat, remove two bolts at the headstock that hold the fuel tank down, prop tank up with tool provided under rear seat, exposing the air box.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step0.jpg

Dissconnect both breather pipes from the air box, use long nose pliers to move the clips. With a firm tug of the air box, this should free the box exposing the carb below.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step1.jpg

Step 2 - Fuel Feed & Throttle Position Sensor Disconnect & Idle Cable
I found that it was easier to remove various Fuel/Sensors/Idle Cables, so that access to the carb covers is easier. The idle adjust knob has to be uncliped from its holder on the left side of the bike.
Disconnect Fuel Feed
http://www.pyroserve.com/tsm/derestrict_SV650K2_step2.jpg

Disconnect Throttle Position Sensor
http://www.pyroserve.com/tsm/derestrict_SV650K2_step3.jpg

Step 3 - Slacken intake duct clamps / Carb removal
To gain easy access to the front & rear carb covers we need to remove the carbs from the engine intake ducts.
Rear carb - Between engine & Carb
http://www.pyroserve.com/tsm/derestrict_SV650K2_step4.jpg
Front carb - Between engine & Carb, Radiator needs to be moved to access clamp.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step5.jpg

Once both the intake duct clamps have been slackened then pull the carbs up by the gold side bars and move to side.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step7.jpg

Step 4 - (Optional) Front carb choke removal
To ease access to front carb cover i decided to remove the front carb choke plunger.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step6.jpg

Step 5a - Part 1 of Removal of restriction kit
This section is the same for the front and rear carbs.
Be very carefull not to let any of the spring fly off in this section
Remove the two screws holding the black cover on the carbs.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step7.jpg
http://www.pyroserve.com/tsm/derestrict_SV650K2_step10.jpg

On removal of the carb cover you will see the diaphragm & piston assembly, remove this carefully so not to damage.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step8.jpg
http://www.pyroserve.com/tsm/derestrict_SV650K2_step11.jpg

Step 5b - Part 2 of Removal of restriction kit
Remove the Jet needle from the piston, as you look into the end of the diaphragm & piston assembly you should see a small grey retainer. Using a long nose pliers, pull and remove. (Becarefull because there is a very small spring and washer that will come out.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step8.jpg
What the Jet needle set should look like.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step13.jpg

Remove the diaphragm from the plastic piston, very carefully so not to damage. As you can see in the picture of the pistons without the diaphragms, the one on the top is the restrictor (with the small hole at the base) the bottom one is the original one which will give you full power.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step12.jpg


Step 5c - Fit original kit
Put diaphragm onto original piston, noting that the diaphragm has to be the correct way arround or it will not seat into the carb correctly.
Re-assemble the Jet needle as it was removed, needle first with washer on the top then spring then retainer.

Place the assembled unit back into the carb. Note that the needle has to be aliged with the small hole on the other side of the carb inlet.
http://www.pyroserve.com/tsm/derestrict_SV650K2_step9.jpg

Once in place place the carb cover in place, becarefull to make sure it seats properly with the diaphragm, screw cover back on.

Step 6 - Put carb back onto engine
Follow in order Step 4 to Step 1, reversing all actions to reatach carbs to engine. Fit air box and make sure that all the breather pipes are attached correctly.


Hope fully this is usefull to people and is understandable.[/b]

[spudnuts]

Dont suppose anyone's got a similar guide with some loverly pictures for idiots for the F1 washer kit, mine is due out in 28 days :)

spudnuts.

[rubianderson]

does this mod apply to USA sv's?

[TSM]

does this mod apply to USA sv's?

Do you have restricted riding licences in the USA? This is to de-restrict from 33hp to Full Power.

Ummmm. dont know.

AFAIK it is for any Suzuki SV650 carb bike (e.g. Curvey Bikes or Pre FI bikes) that has had the genuine suzuki restriction kit installed.

[Saint Matt]

Cheers for that, i might have done it, but tbh i'm happy with it as it is, still shows over a ton on the speedo! Also no worrying, as for the first time i'm completely legal on a bike! (De-restricted moped, de-restricted RS125)

[rubianderson]

does this mod apply to USA sv's?

Do you have restricted riding licences in the USA? This is to de-restrict from 33hp to Full Power.

Ummmm. dont know.

AFAIK it is for any Suzuki SV650 carb bike (e.g. Curvey Bikes or Pre FI bikes) that has had the genuine suzuki restriction kit installed.

No, don't have restricted licenses here in states.
33 hp limit!!! How can motocycle even be fun limited like that?
I had no idea you guys had to live like that.
Sorry

Thanks for reply

[Carsick]

No, don't have restricted licenses here in states.
33 hp limit!!! How can motocycle even be fun limited like that?
I had no idea you guys had to live like that.
Sorry

Thanks for reply
That's only in certain situations where due to age or confidence (or height) somebody isn't able to pass the test on a big enough bike, so have to be restricted for 2 years.
Most of us have the full kind of license.

[Razor]

Good article 8)

[kciN]

Nice article TSM. You're fingers are very dirty, just by taking the airbox off!! :wink:

Oil change before hand was it?? :lol:

[ollie 28]

hello there i tried to deristrict my bike today and realsied that i was never given the standard carb slides when i bought the kit and when the dealer fitted it. do you know of any where i can purchase the slides cheap. there 80 pounds from suzuki.
many thanks

[Jase22]

hello there i tried to deristrict my bike today and realsied that i was never given the standard carb slides when i bought the kit and when the dealer fitted it. do you know of any where i can purchase the slides cheap. there 80 pounds from suzuki.
many thanks

Be cheaper to buy a set of carbs from ebay. That way you've also got spare bits at your disposal.

[Alpinestarhero]

hello there i tried to deristrict my bike today and realsied that i was never given the standard carb slides when i bought the kit and when the dealer fitted it. do you know of any where i can purchase the slides cheap. there 80 pounds from suzuki.
many thanks

Are you sure it came with differant slides? If its an FI international kit, it'll just have two washers - one for each carb.

[BillyC]

Take it back to the dealer and ask for your property back.

[Grinch]

Yep, I would go back to the dealer and be all Oi, you... give.

[benjyman]

hello there i tried to deristrict my bike today and realsied that i was never given the standard carb slides when i bought the kit and when the dealer fitted it. do you know of any where i can purchase the slides cheap. there 80 pounds from suzuki.
many thanks

I've been ringing round suzuki dealers this afternoon and 2 have said it's £170 for parts plus about 1 hour labour. Obviously they might be referring to the washers not the slides but does anyone know anywhere else i could get one?

[plowsie]

I've been ringing round suzuki dealers this afternoon and 2 have said it's £170 for parts plus about 1 hour labour. Obviously they might be referring to the washers not the slides but does anyone know anywhere else i could get one?
Stick a post in stuff wanted and someone should have some mate :)

[Jase22]

I've been ringing round suzuki dealers this afternoon and 2 have said it's £170 for parts plus about 1 hour labour. Obviously they might be referring to the washers not the slides but does anyone know anywhere else i could get one?

I've got a pair of carbs for sale, but Grinch asked me to hold them at the min. If he's not interested, they're here

http://forums.sv650.org/showthread.php?t=117902

[benjyman]

I've got a pair of carbs for sale, but Grinch asked me to hold them at the min. If he's not interested, they're here

http://forums.sv650.org/showthread.php?t=117902

Are the carbs with restricted slides then? Because that's what i need.

What do you think about drilling my own hole in the carb slide? Does anyone know the approx diameter?

[Jase22]

Are the carbs with restricted slides then? Because that's what i need.

What do you think about drilling my own hole in the carb slide? Does anyone know the approx diameter?

Sorry - thought you wanted de-restricted slides, which is what mine are. My bad.

[maultin]

Firstly, great thread, very helpful for when I de-restrict my bike in August '09.
Secondly, any help would he gratefully accepted. Heres my possibly problem. When I bought the bike from the dealer, I had it restricted by them prior to pick-up. When fitting the suzuki restrictor would the dealer have taken out any OEM parts & should those parts been given to me? If so, will I need replacements when I take out the restrictor kit?

Many thanks, Alan

[chakraist]

Woah, megabump!

[Dangerous Dave]

When fitting the suzuki restrictor would the dealer have taken out any OEM parts & should those parts been given to me?
They don't tend too give you the full power pieces back, if you do it yourself you will have to source the parts from somewhere like Robinsons (http://www.robinsonsfoundry.co.uk/shop/index.php/parts/index.html).

[maultin]

Thanks Dave - I think I might go back to Wyder where I got the bike from & see if they are willing to replace the parts for me.

[benjyman]

Okaay, i should get my slides tomorrow but i'm putting restrictors in rather than taking them out. Is the process exactly the same just a straight swap? And when i ordered them i was told there are 2 slides and some washers. Anyone know what these could be for?

[yorkie_chris]

Get the full-power slides back if you have bike restricted by a dealer. They are your property. They have no right to a monopoly on your business after restriction is up! Robbing ****s.

P.s do not drill slides that puts you in same situation... Just put post in wanted section, there's usually some for sale or kicking about somewhere.

[Stu]

Woah, megabump!
I reckon we should have a top 20 of sticked threads in this section - this could qualify 8)

[yorkie_chris]

Yes, putting restrictors in is exactly the same as removing them, just swap slides. with suzuki kit you don't need any washers, just the slides.

[Dangerous Dave]

Get the full-power slides back if you have bike restricted by a dealer. They are your property. They have no right to a monopoly on your business after restriction is up! Robbing ****s.
Actually, the reason why the Curvy restriction is a lot cheaper than the Pointy one is that you exchange your FP slides for the RL ones.

With the Pointy restriction the dealer is asked by Suzuki to look after the ECU for you, you can requested it back as you said Chris.

[yorkie_chris]

So they have monopoly on you going back to them to get work done. Money for old rope.

[Dangerous Dave]

So they have monopoly on you going back to them to get work done. Money for old rope.
Yeah, but you do the swap again for the full power ones and save some money again (if you are a dealer servicer).

[yorkie_chris]

Lol that's like a mugger giving you the shrapnel out of your wallet back to you though!

Still getting shafted

[Dangerous Dave]

Yeah, but some people on here got screwed out of over £300 to pay for the restricted ECU which Suzuki never said they were charging for (hence why they declared it to the press that it is actually free). Same went for derestricting, you gotta admit that is a hell of a lot more expensive that the Curvy!

[tb712]

I've read all your posts on this and the process seems quite straight forward thanks to this guide.

Though abit confused what parts i need to get in preperation for doing this ? Any help please ?

Thanks Tom


2001 curvy 650s

[benjyman]

you need restricted/unrestricted carb slides depending on which way you're going, restricted ones are available from robinsons foundry. unrestricted ones, you're maybe best just getting a pair of carbs off someone on here and taking the slides out. it's not that difficult, just allow a day. i couldn't get one of the caps off and had to drill the screw out, but it's all fine now.

[tb712]

so all i need to derestrict my bike are the unrestricted carb slides ? Brilliant. that also sounds fairly cheap so I am happy with that :)

though the guid on this thread shows some springs, are these just coming out and going back in once the slides have been changed ?

and i assume i need 2 carb slides ?
sorry i have no clue at all am learning as i go !

Thansk

[benjyman]

yep you need a pair, and that's all. the unrestricted ones don't have a hole in the side. this is assuming that yours has this type of restriction, as opposed to the FI things or throttle stop or some other business.

[tb712]

yep. i think so, i got the offical suzuki certificate so i assume thats right - will find out when i open it up at the weekend !!

could you send me a rough link to ebay or equivalent selling place for these, i must be calling them the wrong thing in my search...

Cheers

[benjyman]

http://cgi.ebay.co.uk/SUZUKI-SV650S-SV650-1998-2002-SET-OF-CARBURETORS-CARBS_W0QQitemZ200269625416QQcmdZViewItemQQptZUK_M otorcycle_Parts?hash=item200269625416&_trksid=p3286.c0.m14&_trkparms=72%3A1683%7C66%3A2%7C65%3A12%7C39%3A1%7C 240%3A1318

that's all i can find, which is a complete set of carbs. you'd be able to find these cheaper from someone on here though i reckon.

[AIF]

I've been cheated in suzuki shop in Finland. I assume dealer wants me to bring bike back to him so he can take some money from me.

He sold me unrestricted slides... ones he claimed to be unrestricted but they are with the hole. I wouldnt want to buy new slides again so I'm wondering can I just cover the holes with piece of duck tape?

Also if someone could sell me one unrestricted slide cheap and mail it to Finland I would appreciate it very much :)

[yorkie_chris]

Don't gaffer tape stuff inside carbs, it isn't very good for them...

It'd be hard to mix the 2 up, are you sure they've sold you restrictor kit ones? Can you post a pic?

[AIF]

Don't gaffer tape stuff inside carbs, it isn't very good for them...

It'd be hard to mix the 2 up, are you sure they've sold you restrictor kit ones? Can you post a pic?

This isnt same carb as one inside my bike coz I dont want to go and open carbs at the moment, but this is similar to one inside a bike:

http://img177.imageshack.us/img177/9660/img7771.jpg (http://img177.imageshack.us/my.php?image=img7771.jpg)

At the moment, my front slider is without the hole, and my rear slider is with the hole. Story is pretty long so I wont be going into details. But anyway I got wrong sliders from the dealer.

[yorkie_chris]

Yes thats 33bhp one.

Can you not just take parts back to dealer and say "sort the f##k up out"?

[AIF]

Yes thats 33bhp one.

Can you not just take parts back to dealer and say "sort the f##k up out"?

No. I have had too much problems with this particular dealer, he never backs off and will say that whole world is wrong and he is right. :P Great huh?

is that tape really really bad idea?

Or is someone willing to sell me one slider? here new slider costs 45€

[yorkie_chris]

So he sold you one 33bhp slider and one full power one? Useless tw4t!

Yes tape is a really really bad idea! I will sell you a slider but next week when my exams are over.

[AIF]

So he sold you one 33bhp slider and one full power one? Useless tw4t!

Yes tape is a really really bad idea! I will sell you a slider but next week when my exams are over.

Okay, sounds great. Remmeber that I live in Finland ;) But I can pay you via paypal is that ok?

And I have my exams in few weeks also :)

[yorkie_chris]

Yes, fine. Remind me on Monday.

[Chris1990]

Hello,

I took both restricted diaphragms out and put the unrestricted ones in the carb. Bike is backfiring, then decide to go no faster then 30mph and there was no change in power. Me and my mate went through the step by step again and every think we did was correct. So we decide to put the restriction kit back in. And the bike is now working fine.
Confused to why its not working as i followed your step by step all the way through. Any suggestions on why it is not working?

SV650s 2002 UK

[yorkie_chris]

If you did it all per the book then the sliders you have are defective, and there would be obvious cracks in them.

Otherwise, you didn't seat something or connect it right the first time. Maybe carb rubber or airbox boot

[TSM]

do you balance the carbs afterwards?
did you make sure that the needle did not come loose after you put the slider back in, this can happen?

ps. there is not much between restricted/unrestricted upto 30

[Chris1990]

When i said the bike wouldn't go no faster then 30 mph, i meant to say it was a struggle to get there. The bike pretty much had no power. Put it this way someone on a push bike could of out accelerated me.

I looked at both diagrams, couldn't see no cracks in them. The Airbox was on, when we took the unrestricted diagrams out the needle was firmly in and the rubber was on.

When you say balance the carb, what do you mean?

Is there anything that they can change as well as the diagrams to prevent you form getting full power?

[TSM]

When i said the bike wouldn't go no faster then 30 mph, i meant to say it was a struggle to get there. The bike pretty much had no power. Put it this way someone on a push bike could of out accelerated me.

I looked at both diagrams, couldn't see no cracks in them. The Airbox was on, when we took the unrestricted diagrams out the needle was firmly in and the rubber was on.

When you say balance the carb, what do you mean?

Is there anything that they can change as well as the diagrams to prevent you form getting full power?

Not realy, there are only two restriction kits, the sliders (OEM kit) and the washers (FI kit).

there was somthing not done right, the rubber diaphrams were either not fitted right, nipped when the cover was put on or the needles were pushed out as you put the slider back in.

The sliders only move with the neg pressure caused by the cylinder on the intake stroke. For it to run that badly there must be an install issue i would say.

Where are you based?

[Chris1990]

UK mate

[chris8886]

UK mate

i think TSM means where in the uk?! :rolleyes: :p

[Chris1990]

london

[yorkie_chris]

Not realy, there are only two restriction kits, the sliders (OEM kit) and the washers (FI kit).

there was somthing not done right, the rubber diaphrams were either not fitted right, nipped when the cover was put on or the needles were pushed out as you put the slider back in.

The sliders only move with the neg pressure caused by the cylinder on the intake stroke. For it to run that badly there must be an install issue i would say.


+1 to all.

[szupi]

Hi fellows,
I did not find relevant place to say hello, so I will do it here, with my first post.
Hi, I am Łukasz, 29 yo, I live in Poland.

I am about to restrict a bike (carby hyosung gt650) which is equipped with mikuni carbs, the same like in sv650.
Can anyone give a diameter of a hole that is to be drilled in slides? I have a spare pair of them, so I could give it a shot. I want to make it only for myself, without any documentation or dyno graphs. Could you please help me with it?

Best regards,
Łukasz

BTW. Sorry for digging out such an old thread ;)