SV winter project - rebuild tips? - SV650.org

25-10-12, 05:30 PM

I have a 2000 sv650
Unfaired, 70k miles
Engine runs sweet as a nut
Paintwork shabby and a bit of rust here and there.
I have decided to make it my winter project. Full strip down, repair and repaint. I have never done anything like this before so I hope it goes well. Does anyone have any tips for me to help me on my way? Cheers lads.

Bibio · 25-10-12, 05:32 PM

take photos, take your time and enjoy.

TamSV · 25-10-12, 05:52 PM

I did it a couple of years ago and had never done it before. As Bibio says, take plenty of photos and take your time.

At 70k miles the front exhaust studs will probably be like twiglets. If so, don't even bother trying to get the nuts off - drill them off or use a nut splitter then you can deal with the studs at your leisure.

Bag and tag everything - even the stuff you'll definitely remember.

I kept everything in the same order that it came off so, when I came to reassemble, I just started at the front of the pile and worked my way back.

Get a Haynes manual and a copy of the Suzuki workshop manual. There's useful stuff in one that's not in the other.

If you're patient and methodical it's not at all difficult and just come on here if you're stuck.

Check the valve clearances while you've got the engine out the frame. Makes it a much easier job.

And stick up a thread with lots of piccies - I love reading build threads. Plus, it keeps you motivated because we'll be badgering you for updates.

25-10-12, 08:15 PM

Goodluck m8

muzikill · 25-10-12, 08:52 PM

Follow the tips here. Make a list of what your looking to do on here so we can give advice on what you should do first/last to minimise double work. Pics aplenty. If your not sure about something check and check again, still not sure? ask in here. And well done for making your first step

25-10-12, 09:13 PM

Some good tips, thanks guys. I'm bricking it really as Il probablys have a bag of bolts left after I'm done, lol. But I should be ok. Are those stainless bolt kits on eBay any good? I know for a fact that there's at least 3 heads that's sheared off on the bike in places. So mite as well buy a full set

25-10-12, 09:15 PM

And what's the best stuff for cleaning all the dirty oily parts

Nick_69 · 25-10-12, 09:17 PM

Aslo dont forget if your ot sure please ask the org we wont bite

TamSV · 25-10-12, 09:23 PM

Get a big bag of mixed M6 stainless socket cap bolts in different sizes, washers and nylon nuts from eBay or local engineering place. Will save you loads.

Paraffin's good as anything for cleaning and very cheap.

andrewsmith · 26-10-12, 12:51 PM

Quote:

Originally Posted by TamSV

Get a big bag of mixed M6 stainless socket cap bolts in different sizes, washers and nylon nuts from eBay or local engineering place. Will save you loads.

Paraffin's good as anything for cleaning and very cheap.

This

Seeing your a Northerner, there is an engineering factors in the Durham area and these in Newcastle! I use them quite regularly and they're quite cheap.

If not paraffin, use the contents of the fuel tank and sieve it. Done a frame with petrol as the crap was so bad, paraffin didn't touch it

25-10-12, 05:30 PM	#1
podrikk007 Guest Posts: n/a	SV winter project - rebuild tips? I have a 2000 sv650 Unfaired, 70k miles Engine runs sweet as a nut Paintwork shabby and a bit of rust here and there. I have decided to make it my winter project. Full strip down, repair and repaint. I have never done anything like this before so I hope it goes well. Does anyone have any tips for me to help me on my way? Cheers lads.

25-10-12, 05:32 PM	#2
Bibio Member Mega Poster Join Date: Jul 2008 Location: here as devil's advocate Posts: 11,569	Re: Winter project take photos, take your time and enjoy.

25-10-12, 05:52 PM	#3
TamSV Member Mega Poster Join Date: Feb 2010 Location: Troon, Ayrshire Posts: 1,812	Re: Winter project I did it a couple of years ago and had never done it before. As Bibio says, take plenty of photos and take your time. At 70k miles the front exhaust studs will probably be like twiglets. If so, don't even bother trying to get the nuts off - drill them off or use a nut splitter then you can deal with the studs at your leisure. Bag and tag everything - even the stuff you'll definitely remember. I kept everything in the same order that it came off so, when I came to reassemble, I just started at the front of the pile and worked my way back. Get a Haynes manual and a copy of the Suzuki workshop manual. There's useful stuff in one that's not in the other. If you're patient and methodical it's not at all difficult and just come on here if you're stuck. Check the valve clearances while you've got the engine out the frame. Makes it a much easier job. And stick up a thread with lots of piccies - I love reading build threads. Plus, it keeps you motivated because we'll be badgering you for updates.

25-10-12, 08:15 PM	#4
fatlad Guest Posts: n/a	Re: Winter project Goodluck m8

25-10-12, 08:52 PM	#5
muzikill Member Mega Poster Join Date: Jul 2005 Location: Dunfermline Posts: 1,712	Follow the tips here. Make a list of what your looking to do on here so we can give advice on what you should do first/last to minimise double work. Pics aplenty. If your not sure about something check and check again, still not sure? ask in here. And well done for making your first step __________________ Learn to maintain your bike, take it apart, rebuild the engine & more (using better bolts ), drop it & fix it again! K3 Job c.v: Engine:remove/split/rebuild/refit. Replace:Gearbox,Fuel pump,Gaskets. Piston clean,rings. Overhaul:Throttle body,Injectors,Brakes,Forks. Remove/refit:Exhaust,Radiator,Oil cooler,Throttle,Air filter,Tank. Replace: Oil,Coolant,grease,brake hoses & bleed. Last edited by muzikill; 25-10-12 at 08:57 PM.

25-10-12, 09:13 PM	#6
podrikk007 Guest Posts: n/a	Some good tips, thanks guys. I'm bricking it really as Il probablys have a bag of bolts left after I'm done, lol. But I should be ok. Are those stainless bolt kits on eBay any good? I know for a fact that there's at least 3 heads that's sheared off on the bike in places. So mite as well buy a full set

25-10-12, 09:15 PM	#7
podrikk007 Guest Posts: n/a	And what's the best stuff for cleaning all the dirty oily parts

25-10-12, 09:17 PM	#8
Nick_69 Member Join Date: Jul 2009 Location: Guildford, surrey Posts: 785	Re: Winter project Aslo dont forget if your ot sure please ask the org we wont bite __________________ Was SV650S K9 Now GSXR 600 K9

25-10-12, 09:23 PM	#9
TamSV Member Mega Poster Join Date: Feb 2010 Location: Troon, Ayrshire Posts: 1,812	Get a big bag of mixed M6 stainless socket cap bolts in different sizes, washers and nylon nuts from eBay or local engineering place. Will save you loads. Paraffin's good as anything for cleaning and very cheap.

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