SV650.org - SV650 & Gladius 650 Forum - ECU Restrictor 33bhp for curvey

Here's where they go!

Thanks to Ricardo (TSM) for the 'How to'

How to de-restrict a Mk1 SV
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 amend 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.sv650.org/derestriction/d...50K2_step0.jpg

Disconnect 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.sv650.org/derestriction/d...50K2_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 unclipped from its holder on the left side of the bike.

Disconnect Fuel Feed
http://www.sv650.org/derestriction/d...50K2_step2.jpg

Disconnect Throttle Position Sensor
http://www.sv650.org/derestriction/d...50K2_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.sv650.org/derestriction/d...50K2_step4.jpg

Front carb - Between engine & Carb, Radiator needs to be moved to access clamp.
http://www.sv650.org/derestriction/d...50K2_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.sv650.org/derestriction/d...50K2_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.sv650.org/derestriction/d...50K2_step6.jpg

Step 5a - Part 1 of Removal of restriction kit
This section is the same for the front and rear carbs.
Be very careful 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.sv650.org/derestriction/d...50K2_step7.jpg
http://www.sv650.org/derestriction/d...0K2_step10.jpg

On removal of the carb cover you will see the diaphragm & piston assembly, remove this carefully so not to damage.
http://www.sv650.org/derestriction/d...50K2_step8.jpg
http://www.sv650.org/derestriction/d...0K2_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. (Be careful because there is a very small spring and washer that will come out).
http://www.sv650.org/derestriction/d...50K2_step8.jpg
What the Jet needle set should look like.
http://www.sv650.org/derestriction/d...0K2_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.sv650.org/derestriction/d...0K2_step12.jpg

Step 5c - Fit original kit
Put diaphragm onto original piston, noting that the diaphragm has to be the correct way around 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 aligned with the small hole on the other side of the carb inlet.
http://www.sv650.org/derestriction/d...50K2_step9.jpg

Once in place place the carb cover in place, be careful 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 reattach carbs to engine. Fit air box and make sure that all the breather pipes are attached correctly.