Sabotage 1999 SV650 rebuild - Honda Motorcycles - FireBlades.org
Suzuki Motorcycles Discussion of Suzuki Motorcycles.

User Tag List

 53Likes
Reply
 
LinkBack Thread Tools
post #1 of 91 Old 01-31-2017, 8:42 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Sabotage 1999 SV650 rebuild

Hello everyone, I recently purchased two crappy sv650 to turn into one reliable functional ride. One bike have a blown engine (blue) and one front end damage (red). I'm using the bike with the blown engine to rebuild the one with front end damage. So far I've swapped the ignition switch, cluster, seats, engine covers (front end damage bike covers were leaking). I plan to swap the tail and tank. I purchased a belly pan, going to wrap the muffler, add fork boots, racetech springs, zx6r shock, check the valve (engine runs strong but have 50000 miles. After I sell the donor bike, i hope that my final cost will be around $1000 for a complete decent looking/running sv650.

When the bike is complete, this will be my fifth bike. Yz250 for dirt, 09 zx6r track bike, Roadstar for long trips, and my pride an 09 R1 street superbike build. Two bikes are not street legal, the R1 i never park it when I ride it because of theft concerns and the Road star is just too big that I just sit in traffic with cars. The sv will be my daily commuter to putter around town, avoid traffic and not have any theft concerns. It will likely get more mileage then all of my other bikes.
Attached Thumbnails
20161228_161433_1485913317871.jpg‎   20161228_161422_1485913353341.jpg‎  
IanDoohan likes this.
Sabotage is offline  
Sponsored Links
Advertisement
 
post #2 of 91 Old 01-31-2017, 9:00 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
I made the bike a radiator guard. Very easy to do. You just need some mesh, $7 and insulator $3 at home depot, and car door trim at auto zone, $4.

You measure the radiator, cut the mesh accordingly, use the door trim on the perimeter of the mesh and stick the adhesive insulator onto the door trim when you're ready to affix onto the radiator. You secure with zip ties.

Why make a radiator guard? Because a rock once punctured my radiator and I really do not care for it to ever happen again. All my bikes get guards since. Cheap insurance.

Got a headlight cove. It's a 7" cover which fits the 7" headlights exactly. My options to mount them on was with heat resistant super glue or drill into the cover and mount them on with some straps of some sort. I think i like the glue option better. It's cleaner and less work so that's what I went with.
Attached Thumbnails
20170123_143207_1485914197885.jpg‎   20170123_144137_1485914443570.jpg‎  
IanDoohan likes this.

Last edited by Sabotage; 01-31-2017 at 10:12 PM.
Sabotage is offline  
post #3 of 91 Old 01-31-2017, 9:19 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
So far here is a picture of the stuff I'm stocking up on. It's like everyone on the sv forum uses rostella t6 engine oil so that's what I went with. The sv650 suspension is a pogo stick so racetech emulators with springs up front and 07 zx6r shock in the rear. All balls fork seals, hot cam shim kit, spaymax 2k clear, belray fork oil and belly pan to sum up the part.

The red bike also came with a dull ass scratched up wind screen that I sanded down and compound clear again then sprayed it with a tint spay.
Attached Thumbnails
20170131_210606_1485915538972.jpg‎   20170129_201900_1485915562525.jpg‎  
IanDoohan likes this.
Sabotage is offline  
Sponsored Links
Advertisement
 
post #4 of 91 Old 01-31-2017, 9:48 PM
President Team Full Chat
 
IanDoohan's Avatar
 
Join Date: 06-28-2013
Location: Connecticut,USA
Age: 45
Posts: 5,620
Images: 4
Mentioned: 33 Post(s)
Tagged: 2 Thread(s)
Quoted: 241 Post(s)
Reputation Power: 74
                     
Garage
Re: Sabotage 1999 SV650 rebuild

You're an obsessive project maniac, with far too many motorcycles, professionally diagnosed by Dr. Doohan


Sabotage and spagiratwink like this.

My 99 900RR Track Build Link:Track Build 900RRX

My Red Rocker 93 Build Link: Café 900RRP
IanDoohan is offline  
post #5 of 91 Old 01-31-2017, 10:10 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Quote:
Originally Posted by IanDoohan View Post
You're an obsessive project maniac, with far too many motorcycles, professionally diagnosed by Dr. Doohan ...
Honestly, this obsession really help me decompress. When life frustrates me, I wrench. Some yell, some drink, some become abusive. Me, i tinker with my toys. Best therapy ever.

Now I just need someone to talk me into getting rid of them when I'm done...
IanDoohan and spagiratwink like this.

Last edited by macca9540; 02-21-2017 at 1:32 PM.
Sabotage is offline  
post #6 of 91 Old 02-01-2017, 8:49 AM
 
Join Date: 04-16-2011
Location: Monongah,West Virginia
Posts: 230
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 15 Post(s)
Reputation Power: 7
 
Re: Sabotage 1999 SV650 rebuild

[quote=Sabotage;1699238521]
Quote:
Originally Posted by IanDoohan View Post
You're an obsessive project maniac, with far too many motorcycles, professionally diagnosed by Dr. Doohan

Now I just need someone to talk me into getting rid of them when I'm done...
I love SV's, I want one. I actually own 5 bikes now myself. A PW50 my brother in law was going to throw in the garbage. You need a HONDA!
coalminer frank is offline  
post #7 of 91 Old 02-01-2017, 10:07 AM
President Team Full Chat
 
IanDoohan's Avatar
 
Join Date: 06-28-2013
Location: Connecticut,USA
Age: 45
Posts: 5,620
Images: 4
Mentioned: 33 Post(s)
Tagged: 2 Thread(s)
Quoted: 241 Post(s)
Reputation Power: 74
                     
Garage
Re: Sabotage 1999 SV650 rebuild

Quote:
Originally Posted by Sabotage View Post

Honestly, this obsession really help me decompress. When life frustrates me, I wrench. Some yell, some drink, some become abusive. Me, i tinker with my toys. Best therapy ever.
More truer words have never been spoken. There is nothing like having a bike in front of you that needs wrenching. It truly is therapudic, but more so when the end result is exactly what you were looking for, lol, sometimes it can drive me nuts. But as you said, it's something that keeps us focused and out of "trouble"
Sabotage and spagiratwink like this.

My 99 900RR Track Build Link:Track Build 900RRX

My Red Rocker 93 Build Link: Café 900RRP
IanDoohan is offline  
post #8 of 91 Old 02-01-2017, 10:54 AM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Re: Sabotage 1999 SV650 rebuild

[quote=coalminer frank;1699238729]
Quote:
Originally Posted by Sabotage View Post
I love SV's, I want one. I actually own 5 bikes now myself. A PW50 my brother in law was going to throw in the garbage. You need a HONDA!
Hey frank, you still lurking around here. I felt the same way about the SV. It's all over the paddocks during track days. Even though this is my street bike the reason I'm building up the suspension is to be able to take it to the track once or twice. And dam it frank don't temp me with that pw50, I have kids you know...
Sabotage is offline  
post #9 of 91 Old 02-06-2017, 7:24 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Did some work on the bike today. I had some black vinyl wrap so I put a black strip on the tank and compounded it to a glossy shine. I pulled the forks off the donor bike to do the racetech internal upgrade. The upgrade involed springs, emulators, and a preload adjuster cap. I made a tool to take off the bolt at the bottom of the fork to remove the damping rod. The tool would fit my impact gun to make the removal a piece of cake. What a PITA it turned out to be to remove the damping rod. The thing kept spinning inside the tube, and that was with the forks still assembled. After I was making no progress, I took the forks apart and jammed the wood end of my shovel in there. Man power alone was not enough to keep it from still spinning so I used my ratchet strap to put more pressure into the damping rod with the shovel. One leg agreed with my efforts while the second continue to spin with every impact from my gun. I finally decided to try my mapp torch on the bolt and it was a successful decision. Last thing I did, before calling it a day, was organize the fork internals to make sure I had everything properly set up for the next stage of the fork rebuild build.
Attached Thumbnails
20170206_172808_1486424995022.jpg‎   20170205_160125_1486425040144.jpg‎   20170205_160111_1486425065316.jpg‎   20170206_184638_1486425095405.jpg‎  

Sabotage is offline  
post #10 of 91 Old 02-08-2017, 8:19 AM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Drilled the damping rods last night. Racetech instructs you to drill two new 5/16 holes and open the other four to 5/16 as well. Cleaning it was a PITA. It took forever to remove every single metal shaving out of there. It felt like I went to the beach, where you just keep finding sand on you after like 100 showers.

At first I was going to gamble and use the original crush washers to reinstall the damping rod and bolt, but i decided against it. I just went ahead and ordered new ones. I'll cut the spacers to give a 10mm preload setting. The adjustable preload adjusting cap I bought will allow me to add up to 30mm of preload if I cut the spacers at 10mm.

The red bike I'm building up, the previous owner told me the shop just did a fork seal and oil for him and was leaking from the bottom of the fork. I bet they gambled and used the same crush washers. I hope my order arrives quickly, I want to finish putting the forks back together already.

Besides the damping rod, I'm working on fitting some fork gators onto the fork for that retro look. The gators I ordered were too small and I could not find any large enough to fit my forks so I cut them and will customize it somehow to give it the look I'm aiming for without affecting the forks function.
Attached Thumbnails
14865596472931907892530_1486559671583.jpg‎   1486559682642-63833237_1486559699621.jpg‎   20170207_204815_1486559719139.jpg‎  

Last edited by Sabotage; 02-08-2017 at 8:58 AM.
Sabotage is offline  
post #11 of 91 Old 02-08-2017, 8:32 AM
President Team Full Chat
 
IanDoohan's Avatar
 
Join Date: 06-28-2013
Location: Connecticut,USA
Age: 45
Posts: 5,620
Images: 4
Mentioned: 33 Post(s)
Tagged: 2 Thread(s)
Quoted: 241 Post(s)
Reputation Power: 74
                     
Garage
Re: Sabotage 1999 SV650 rebuild

I love the pics and updates, very happy you started this thread!


My 99 900RR Track Build Link:Track Build 900RRX

My Red Rocker 93 Build Link: Café 900RRP
IanDoohan is offline  
post #12 of 91 Old 02-08-2017, 9:12 AM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Quote:
Originally Posted by IanDoohan View Post
I love the pics and updates, very happy you started this thread!

Thanks Ian, having the members here as part of my builds makes is much more fun.

So here's a little preview of the gators progress.
Attached Thumbnails
148656311659790608919_1486563141789.jpg‎  
Sabotage is offline  
post #13 of 91 Old 02-11-2017, 10:22 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Today I went and bought a pipe cutter to cut my spacer tubes. After I cut the tubes to allow 10mm of preload, I was ready to put the fork back together. The order it went back together in was damping rod, emmulators, oil, spring, washer, spacer washer, fork cap.

Now that the forks are together, I can install them on the bike and move on to something else.
Attached Thumbnails
20170211_213007_1486869710330.jpg‎   20170210_201426_1486869740852.jpg‎  
IanDoohan likes this.
Sabotage is offline  
post #14 of 91 Old 02-13-2017, 9:43 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Very excited, my steel braided lines arrived today. These lines are from an 03 and up model that fits. I got them for $30 with shipping. They are basically brand new so it was a must i buy them. I had to buy a double banjo bolt, which I found on eBay for my 99 model for $3. When it arrived, I was a little upset that the seller sent me a rusted old bolt which looked nothing like the picture on line. He likely kept it in the elements until it sold. I'm going to see if I can salvage it before I toss it. I'm currently giving it a vinegar and salt bath. After two days, it's looking great.
Attached Thumbnails
1487040073444-1874144029_1487040096339.jpg‎   14870401144941975242432_1487040165903.jpg‎   20170212_123933_1487040204928.jpg‎  
IanDoohan likes this.
Sabotage is offline  
post #15 of 91 Old 02-14-2017, 7:57 PM Thread Starter
 
Join Date: 08-10-2013
Location: New York
Posts: 976
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 48 Post(s)
Reputation Power: 16
                 
Here is the banjo bolt after the vinegar and salt bath. I dumped some Baking soda into the bottle to bubble up and break up any loose rust. Then I swirled it in a baking soda and water blend to neutralize the acid, then I cleaned it with water, then completed the cleanse with a gasoline and premix mix. It looks good to me...
Attached Thumbnails
20170214_193109_1487120223315.jpg‎   20170212_123933_1487120277524.jpg‎  
Sabotage is offline  
Reply

  Lower Navigation
Go Back   Honda Motorcycles - FireBlades.org > Other Motorcycle Brands > Suzuki Motorcycles

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Honda Motorcycles - FireBlades.org forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
A valid e-mail address is REQUIRED. You will not have access to any site features until you activate your account using the activation e-mail that is sent to this address.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Forum Replies Last Post
00 CBR sabotage repair. BDLJUICE General Discussion 5 05-12-2014 2:44 AM
To rebuild or not rebuild this is the question? NICE954 General Discussion 5 02-22-2010 4:21 PM
FS: Custom '06 SV650 Chain For Sale 62 10-11-2006 9:59 AM
Used SV650 pricing Q Northern RR Suzuki Motorcycles 10 04-09-2006 7:17 PM
New Sv650 killer? G-Force Junkie General Discussion 1 09-02-2005 3:18 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

 
For the best viewing experience please update your browser to Google Chrome