DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: gt alex on Sep 23, 2018, 02:36:42

Title: budget sv650 cafe racer
Post by: gt alex on Sep 23, 2018, 02:36:42
Dispite being a budget build I am keen to make this a great bike to ride and to look at.
Already fixed the road worthy bits, and today trial fitted the clip ons and mirror, thinking of keeping the old risers to mount my G Tech RR for performance testing
Title: Re: budget sv650 cafe racer
Post by: gt alex on Sep 24, 2018, 01:48:20
short levers went on today and tonight I pick up a2nd gen motor to get the intake cames from. using my intakes in the exhaust and the 2nd gen intakes in the intake should deliver 5-8hp
Title: Re: budget sv650 cafe racer
Post by: CrabsAndCylinders on Sep 24, 2018, 01:51:19
That's neat, are the 2nd generation intakes shorter, or bigger in diameter?
Title: Re: budget sv650 cafe racer
Post by: gt alex on Sep 24, 2018, 01:54:08
just relized I didn't post a start picture
Title: Re: budget sv650 cafe racer
Post by: gt alex on Sep 25, 2018, 06:37:04
started fitting gear side rear set today
Title: Re: budget sv650 cafe racer
Post by: gt alex on Oct 05, 2018, 06:23:57
The rear sets are on and adjusted to suit the standard seat at this time. I am waiting on a bango switch for the rear brakes. the kit came with parts to adapt the original mechanical switch, but I must be a bit dumb, I could not see how it would work so i'm just going with the Hydraulic switch.
I am still waiting on my dba meter (should be here soon) for muffler tests and I have ordered a harley drop in lowering kit Which I hope will supply parts for some more mad scientist suspension experiments. still can't afford my adjustable rear shoch and spring but it will happen.
The idicators clear the bars now. I have just bent them to the same angle as the bars.
Title: Re: budget sv650 cafe racer
Post by: pidjones on Oct 05, 2018, 08:10:48
There are lots of sound level apps for "smart"phones. Don't know how well they work or how accurate they are. I even have one on my Windows phone.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Oct 05, 2018, 09:48:13
I tried 2 sound meter apps on my android phone both gave very different results. it didn't show much difference idle to 6000rpm. We will see what a dedicated meter shows.
Title: Re: budget sv650 cafe racer
Post by: Odontologist on Oct 07, 2018, 03:52:40
Cool. Was it originally a naked or an S? The S came with rearsets I think...just wondering if new sets are greatly different to standard on the S. Great bikes BTW.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Oct 08, 2018, 03:21:42
It was a naked, and I think the S rearsets are about an inch back and up. these ones are about 3 inches back and 11/2 up approx. I just held the old ones up next to them and eye balled it.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Oct 09, 2018, 07:35:26
The dba meter arrived today the staintune muffler that came on the bike measured 84dba at idle and 98dba at 5000rpm so it looks like it will be a challenge to find a shorty that stayes under 94dba without being to restrictive. I thinking  dual mufflers might add some volume and each one could be more restrictive because they would share the flow.
Best shorty tested so far is 89 idle and 100dba 5000rpm.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Oct 11, 2018, 05:13:09
I have been playing musical mufflers. The staintune is gone and I have settled on the short muffler from my old VW kombi. Getting the sound and baffles right is still on going. I have been thinking of fitting discs a bit like supertrap style
Title: Re: budget sv650 cafe racer
Post by: gt alex on Oct 14, 2018, 02:43:28
Just doing some more testing, making disc baffles from drain strainers. By lining up the straining holes a spacing to let the exhaust through and then using the theads on a central bolt to space them evenly approx. 1/2 mm apart and blocking the end (just with a rag for testing.)
It seems to work well, Im just not sure if relying on the center hole will be to restictive WOT. I don't think it would be worse than other DB killers plugging the end.
With this layout I could use 1/2 mm thick washers for consistant spacing. I only had 5 discs but back pessure and sound seem on track.
Title: Re: budget sv650 cafe racer
Post by: pidjones on Oct 14, 2018, 18:27:55
Interesting. I tried one washer covering ~ 50% of the area ~1" after the baffle on each side of my GL1000. Held in place with large pop rivits to three 1/4" tubing sections each. Within ~ 40 miles it spit them out. Ripped the large pop rivets right out.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Nov 03, 2018, 06:01:15
I got a bug and was out off action for a week,I still have to weld the exhaust, but parts still arrived the bango switch for the rear sets. unsure which thread my year sv had I ordered both 1mm and 1.5mm pitch at only $4 each still good value and I won't get stuck. The other thing that arrived which won,t be fitted till the hump frame is going on, the rear shock, fully adjustable comp & rebound 8mm shorter than standard so I will need to revisit the rear height. spring rate still unmeasured.
Also the harley dropin lowering kit arrived I hoped the main spring would be about .95kg/mm but is is so stiff I didn't even bother checking(spares)
Title: Re: budget sv650 cafe racer
Post by: gt alex on Nov 03, 2018, 06:53:29
pictures of above
Title: Re: budget sv650 cafe racer
Post by: gt alex on Nov 05, 2018, 06:07:42
Today I fitted the rear brake bango bolt switch. and fixed the way the rear brake line was run. Because the rear sets changed the mounting angle of the rear master cyl. The brake line at the master cyl end kinked the line up after fitting the rear sets so I just rotated the line so it would point along the swingarm. Since it fitted both ways I may get a straight fitting when I change to a braided line.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Nov 09, 2018, 08:27:07
Today I welded the muffler to the center pipe I cut from a staintune (used 2.5mm 316 stainless rods with a inverter stick welded the linished with a flapper wheel) and modded a double barrel dbkiller I made as an experiment. I added a end plate and cut slots with a grinder and packed it with stainless steel wool. the dbkiller was ok before the mods 105dba measured 1/2 metre from pipe 45deg @5000 rpm with mods it dropped to 100dba. Will do if the disk baffles don't pan out
Title: Re: budget sv650 cafe racer
Post by: gt alex on Jan 28, 2019, 07:45:01
Ha hooo! got the safety cert. and will be on the road soon. Still working on a mount for my "g tech rr".
I made it a single seater but won't be putting the hump seat on till It is sorted a bit and I have some base perfomance figures.
I will be making more posts as i go
Title: Re: budget sv650 cafe racer
Post by: gt alex on Feb 09, 2019, 10:53:22
been working on a rear seat replacement cowl
Title: Re: budget sv650 cafe racer
Post by: gt alex on Feb 10, 2019, 08:00:27
A bit of filling and sanding and it will be ready to pull a mould
Title: Re: budget sv650 cafe racer
Post by: gt alex on Mar 28, 2019, 07:02:25
Been bit busy but getting back to the bike. got all the fiberglass stuff last week and today got the muffler baffling to a legal level but now thinking of building a valve and a second stage in the disc assembly to releave backpress over 6000 rpm since the legal test requirement is 4500rpm
Title: Re: budget sv650 cafe racer
Post by: gt alex on Apr 11, 2019, 08:01:48
The exhaust is sorted, still needs a tidy up
Current state
basic muffler 14" long, 4" dia, glass packed 2" core
Mod 1, twin 1'pipes with slots and holes with 2" baffle each end and stainless steel wool, inserted and welded in muffler. 107 dba 4500rpm
Mod 2 home made disc type muffler fitted with 4 discs. 93 bda 4500rpm
Mod 3 spring loaded end plate on disc pack which prevents excessive back pressure, opens 6000 rpm free reving no load.
now needs epa label on bike and muffler stamped

And today
Since I have many mods planned and want to make sure they do what I hope to day I made a braket and mounted my G tech pro RR and calibrated it. All except the weight (not sure how I'm going to weigh the bike?)
Title: Re: budget sv650 cafe racer
Post by: wozza on Apr 11, 2019, 20:10:06
to weigh the bike get a set of bathroom scales, make a ramp the same height as the scales out of wood. Roll front wheel on then the back and add up the sum total, wont be spot on but in the ball park


edit you can also go to a recycle center, garden supply (sells top soil gravel ect) and use their weigh bridge 
Title: Re: budget sv650 cafe racer
Post by: gt alex on Apr 15, 2019, 09:29:08
Apparently the local council have a local weighbridge.
I previously fitted lowering dog bones to my cafe racer project but the shock I bould is 8mm shorter than standard so I put the standard dog bones back in since it will be lower anyway.
I all so took the oppertunity to measure with the rear fully dropped with the lowering links and the standard links. measuring this time it looks like 45mm difference.
Also a good chance to show my stand in use.
Now the old shock is out and scratching my head the best way the fit it as it has 12mm monting holes not 10mm. drill everythine for 12mm bolts or fit spacers in the holes.

Title: Re: budget sv650 cafe racer
Post by: gt alex on Apr 19, 2019, 11:53:33
Today the rear shock went in, only mods required were some alloy tubing to use 10mm bolts with the shock (designed for 12mm) and the bottom fork of the shock required a longer bolt and a nut (the original used a thread in the fork) this required longer dog bone bolts and spacers on the left side.
Also I had to recess the bottom of the battery tray 5mm.

Tomorrow I will set it up and hopfully the spring rate will be in the ball park. a quick check looked promissing 20mm static sag and 55mm total before doing any adjustments.

Better than the oem 5mm static and 55mm total was the best ajustment I could get (i don't like runing less than 5mm static)

Then there's the rebound and compression rate to do.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Apr 20, 2019, 07:20:34
shock install pictures
Title: Re: budget sv650 cafe racer
Post by: gt alex on Apr 24, 2019, 09:35:44
Been test riding with new shock.
Results clear as mud.
Still think the front is compression too firm (was too soft) had gold cartridge emulators (effect compression) but didn't change the adjustment just put in 15w oil, think rebound still bit soft?
Rear was set 10 clicks of 20 on compression and 5 of 14 on rebound. thought it was great till I hit a big rut and launched my bum.
So trying to match front and back I pulled the emulators out of the forks and adjusted them 2 1/4 turns of preload (comended 2-3 for steet they had 7 turns) upon reassembly seems bit soft, maybe 20 w oil so I can bump up rebound and compression.
And at the rear I made drastic changes both rebound and compression on softest both only 1 click (still feels well damped, probably bit soft on compression)
I will see how it rides tomorrow. That will be my starting point, then I will start changing 1 thing at a time.
Roads are rubbish round here but they are twisty wish me luck.
Title: Re: budget sv650 cafe racer
Post by: gt alex on Jun 16, 2019, 08:50:26
Been a while but I have been enjoying riding a bit rather than working on the sv650.
all seemed good till the other day when my lithium ion battery arrived and after checking charge voltage with the old battery still in place (14.5v ). I decided it was all go for the the new battery, which I fitted with the spacer blocks provided.
Next morning cold started well second go with some choke. By the time I got to the street the tacho stopped working, then about a km down the road the bike stopped.
It blew the tacho, cdi, head light, and the new battery, all I can think is the rectifer regulator died taking the rest with it.
So I contacted the battery supplier who implied I had a faulty regulator all along but I think I was bad luck.
The battery supplier has offered a good deal on a replacement but I a am a bit gun shy now

What do others think try again?

I got a cdi for gumtree and ebay RR on order.
while need to wait for money for the rest hopefully nothing else blew.

In the mean time since I can't ride I have started the hump seat conversion.