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Old 12-13-2010, 03:19 PM   #1 (permalink)
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Default SV650 rebuild-Streetfighter

I noticed a few guys on here have sv's, so I figured I might share my recent rebuild project.

This was the bike when I first got the keys to it, back in 2007.



Before I put it on the road, I took the clip ons off and went with the stock bars.


After a year of riding it, I hit some sand and ended up in a guardrail.



This is when the rebuild started, first purchase was a 2002 gsxr 750 front end

Last edited by robertw; 07-01-2013 at 08:08 AM.
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Old 12-13-2010, 03:23 PM   #2 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Front forks on, I had to get a different set of bearings for the forks.





The rear gsxr shock in, and the battery moved, and battery box built around the shock reservoir.


Raised battery.


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Old 12-13-2010, 03:29 PM   #3 (permalink)
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Default Re: SV650 rebuild-Streetfighter

The bracket for the buell headlight assembly that was made.



I purchased the trailtech tach kit, pretty commonly used over on svrider. Had a bracket made to install the tach onto the vortex triple.



All lights working, used a radio shack led under the oil pressure idiot light to use for my high beam indicator. There wasn't enough openings for all the lights, so it was decided to drill a hole and just wire one in.


All wired up, only missing thing is the speed sensor.
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Old 12-13-2010, 03:46 PM   #4 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Some more things that needed to be replaced



Some cheap blinkers


Clip ons installed and a gsxr fender I was going to use until I found a replacement to get painted.



Purchased a belly pan for the bike.


Made an adjustable speed sensor mount for the trailtech kit.


Here are the parts back from paint and body.



Back together again.





When I finally got it back on the road.


Had a few hiccups along the way, getting the stock fuel senor (low fuel sensors in the tank) to work with the trail tech, I had to put a few resistors on the line since the sensor was wired into a mother board with the factory tach. The light fades in now vs just turning on solid once fuel is low. But at least I still get an indication when I begin running low on fuel.

I also had issues with my carbs, I couldn't get the bike to run right for the longest time. I ended up bringing to a suzuki dealer ship to have it fixed. Ended up having a bent throttle cable bracket at the carb, go figure. Also had it sync'd and jetted since I removed the baffle in my stock exhaust.

Thanks for checking the thread out
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Old 12-13-2010, 03:48 PM   #5 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Nice work man looks way fun, enjoy it........again lol.
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Old 12-13-2010, 03:51 PM   #6 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Cool. Good job on the bike...turned out nice and clean.
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Old 12-13-2010, 03:52 PM   #7 (permalink)
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Default Re: SV650 rebuild-Streetfighter

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Nice work man looks way fun, enjoy it........again lol.
Haha thanks, it's much more fun to ride now, and I ride muuuuch more carefully these days. Hopefully I get some use out of the bike next year now that I picked up a NA lol.
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Old 12-14-2010, 04:52 PM   #8 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Wow - what a transformation. I would of threw in the towel after a crash like that.
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Old 12-14-2010, 05:37 PM   #9 (permalink)
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Default Re: SV650 rebuild-Streetfighter

It looks so... angry!! Nice build!
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Old 12-14-2010, 08:19 PM   #10 (permalink)
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Default Re: SV650 rebuild-Streetfighter

I have an 04' SV650 in yellow. Because it's the fastest color.
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Old 12-14-2010, 08:39 PM   #11 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Nice build

I've always wanted a SV now that I'm married and have a kid on the way there is no way in hell the wife will let me get another bike....... Cant wait till the midlife crisis then I'll get my Bike and have a reason to tell her to STFU
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Old 12-14-2010, 09:37 PM   #12 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Those are some sweet brackets you got. Custom made??
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Old 12-15-2010, 07:44 AM   #13 (permalink)
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Default Re: SV650 rebuild-Streetfighter

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Those are some sweet brackets you got. Custom made??
Yes, my dad made the headlight and tach bracket at his shop for me.
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Old 12-15-2010, 01:07 PM   #14 (permalink)
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Default Re: SV650 rebuild-Streetfighter

damn jealous.....by the way, copper is the fastest color.
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Old 02-22-2012, 09:14 PM   #15 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Well got around to trying to finish my bike, been a few years, slacking. Picked up an 06 gsxr 600 wheel

left stock, right gsxr not a huge difference




Just need to get the sprocket carrier from the gsxr wheel and the caliper bracket from sv machined, and hopefully everything just bolts right up after that.
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Old 02-22-2012, 09:25 PM   #16 (permalink)
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Default Re: SV650 rebuild-Streetfighter

wow that looks great! can you ballpark costs of this?
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Old 02-22-2012, 10:01 PM   #17 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Not sure anymore, but it's up there at this point.
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Old 02-22-2012, 10:43 PM   #18 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Ballpark figure, well its an SV so about $50 including the bike. Lol Great looking bike and i knew i had seen that last pic on SVR before. I'll get something else one day, but for the last few years there has been nothing that can do it all for me like an SV.
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Old 02-23-2012, 10:34 PM   #19 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Well sent my parts out, now on with the waiting.
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Old 02-24-2012, 08:09 PM   #20 (permalink)
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Default Re: SV650 rebuild-Streetfighter

hoozaa, ordered an 04 ninja 636 rear shock to replace my gsxr rear shock out back. Hopefully this eliminates the rear sag.

Bored waiting on parts...so I took a pic


I also need some new rea rsets since I scrape these stockers everywhere. Not sure how wild I want to go, maybe woodcraft, or just save a few bucks and get the svs rear sets. So either up and back approx 2" or up and back 1". The woodcrafts may be more than I need but they do look awfully nice

Last edited by robertw; 02-24-2012 at 11:02 PM.
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Old 02-25-2012, 02:21 PM   #21 (permalink)
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Default Re: SV650 rebuild-Streetfighter

I think it was SVRacing parts that i got my stock rearset risers. They move the pegs 1in. up and 1in. back. Pretty cheap too. Under $25 IIRC. Search SVRider, great way to do it on the cheap. Also remove the nub on the end of the pegs.
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Old 02-25-2012, 02:34 PM   #22 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Hey thanks that was a huge help, never even knew about those lol. I ordered the non adjustable ones, 1" up 1" back, in silver.
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Old 03-01-2012, 08:26 PM   #23 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Wow! Glad your ok. That bike took a beaten.
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Old 03-01-2012, 10:47 PM   #24 (permalink)
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Default Re: SV650 rebuild-Streetfighter

nice build, spend some of that money on some proper gear
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Old 03-02-2012, 04:27 PM   #25 (permalink)
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Default Re: SV650 rebuild-Streetfighter

I had a jacket, gloves, and helmet when I went down. Maybe leathers this season.

Got some parts, going to try and get some work done this weekend.

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Old 03-02-2012, 04:42 PM   #26 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Very cool - one of these days I want to do a build on a sport bike. Not sure what direction I want to take one yet though. For now I just want to get a sport bike back in the stable to compliment my DR650 motard.
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Old 03-03-2012, 08:51 AM   #27 (permalink)
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Default Re: SV650 rebuild-Streetfighter

Well I dug up my old stock shock and compared it to the gsxr shock I had on the bike, the gsxr shock was approximately 1" shorter than the stock shock. That would explain my bikes gangster lean. The 636 shock is in fact the same length as the stock sv shock. I also wasn't anticipating the 636 shock swap to be much more work than just a simple removal of gsxr shock, swap 636 in, and bolt everything up. This has turned into a much more involved project lol.

The battery box I modified for the gsxr shock doesn't work with the 636 shock. The reservoir on the 636 shock is significantly wider, and sits higher up. I also need to trim or mod my gas tank bracket, atm I cannot get it on due to the reservoir being in the way, so I'll either trim that lower piece, or shorten it and weld it back together.

Here some pics...





Other than the battery box issue, and tank bracket clearance problem the fit is decent enough. No other real clearance issues.
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Old 03-03-2012, 11:59 AM   #28 (permalink)
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Default Re: SV650 rebuild-Streetfighter

If the GSXR shock is still good, why not just get some raising dog bones. You can get 1in. 2in. and I think 3in. Then your ride height will be fixed and you won't have to re-mod the battery tray and tank bracket.
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Old 03-05-2012, 09:45 AM   #29 (permalink)
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Default Re: SV650 rebuild-Streetfighter

I probably should have done that, but now that the shock is in, I don't want to take it back out lol. But at the same time the gsxr shock had some plastic shielding melt on the shock from the exhaust . I think I have the battery box issue squared away with far less drama than I had initially anticipated.

I should have it back together this week (hopefully), photo dumb in bound.
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Old 03-05-2012, 10:00 AM   #30 (permalink)
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Default Re: SV650 rebuild-Streetfighter

nice turn around on the bike. . . this is the first tubed style framed SV i actually like

I'm def feelin it!
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