2004 SV650 Neo Classic Cafe Fighter

Hurco550

Keep er' Between the Ditches
DTT SUPPORTER
DTT BOTM WINNER
Is that good enough? Did I use a sufficient enough amount of motorcycle buzzwords in the title to say "trying to knock some modern" off of a street bike? I hope so, because that's the plan.

About a month ago, I picked up this 2004 Suzuki SV650 from some kinfolk of the illustrious @VonYinzer over towards Steelers land in PA. The bike had been sitting unused since about 2015. Life has taken a bit of a turn lately, which led me to thin out the stable some; though it wasn't the way I would have planned for that to happen, it was a much needed endeavor anyways. The herd had been paired down to my little dr650 hardtail bobber, and my old airhead which is sporting north of 100k miles. A good old bird, but still that, a bike that's a bit long in the tooth with many miles behind it. During that time, I had become the caretaker of my father's 2005 Buell Xb12s while he recovered from open heart surgery. I put a couple somewhere around a couple thousand miles on it during the season, and while chasing @Chuck78 and a few of his much better skilled friends around the amazing twisties of South Eastern Ohio, I realized that that was the genre of bike for me. Not overly powered, but fantastic handling on a medium sporty riding position bike was what fit the bill. Thankfully dad is well on his recovery, and the buell is back in his possession.
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Mike (vonyinzer) had mentioned that the SV may be available over a year ago, and as things turned around and I had a skiff of cash in my pocket, I decided that I'd go after the bike. As it sat, it was a pretty decently setup little bike. His brother in law had put a nice set of R1 usd forks on it with 2" rise clip ons, a gsxr reservoir rear shock, 2 Brothers exhaust and a few other things. I collected the bike, handed him a very fair amount of cash, and towed the bike back to Ohio.
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As mentioned before, the bike has sat for about 8 years, and as so, it needed a bit of care. Cracking open the tank revealed some less than savory surface inside.
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Lucky for me, I've had plenty of experience with rusty old fuel tanks, and gave it my usual treatment, which left it plenty serviceable. I am convinced that my garage will now smell like old varnished gas for all of eternity though.
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Upon further inspection and re assembly, I found that the in tank fuel pump had given up the ghost, so I put one on order and continued on.

Nothing says a bike has sat in storage for 8 years quite like opening up an air box to this...

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Thankfully the mice didn't make it through the air cleaner.
 
I do think that in stock form that the naked SV650's are good looking machines, but as most of us here, I enjoy a bit of a retro vibe and the factory subframe and tail section was just a bit too "early 2000's sportbike" for my liking. I ended up buying a pair of these "wrapped cafe seats" that used to be for sale by Dime City Cycles. I purchased them from the guy that made them for DCC and had two left over. After pulling the stock subframe off and throwing this on there, I decided that it was a good direction to head.
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With a bit of measuring and Autocad work competed, I made up a quick and dirty aluminum subframe.
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After putting it on the bike, I was able to confirm that I liked where the seat was positioned and it was a comfortable enough seating position. Though it may look extreme, it's actually in the same position that the factory seat was in.
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Though I'm going to likely jettison the aluminum plate design in favor of one built from chromoly tubing, I am happy with where it puts everything and I feel that the proportions and position are where they should be. I am also using a spare tank during mockup as to not scratch the nicer one, but it has me thinking that the stock one may end up needing resprayed in black as well..
 
cool project. the 2nd gen frames look way better than the 1st gen to me.
 
As long as the Autozone crotch pad goes from tank to thank, I'm on board.
 
Thanks yall. I appreciate the kind words. The more I looked at it, the less I liked the subframe myself. It just had too bulky of a design, so I decided that I would fab one up out of chromoly. I still have to make the "bottom struts" but im getting close. I think it will look nice when done, though tidying up the wiring and hiding it under this seat will be a bit more of a challenge.

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Got the main part of the subframe done. Now to build up a battery box and tidy up the wiring..
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Now you're just showing off!

Nice work!
 
Is that a Kovosu fixture table? looks super nice. I have a Certiflat and its OK. I have been thinking about getting something bigger and the Kovosu seems like good value for the money
 
Is that a Kovosu fixture table? looks super nice. I have a Certiflat and its OK. I have been thinking about getting something bigger and the Kovosu seems like good value for the money
It's a seigmund 5x10 imperial (5/8" holes 2" on center)

A good fixture table is a game change for sure!
 
Got the main part of the subframe done. Now to build up a battery box and tidy up the wiring..
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Nicely done, however, not to be nitpicky, but, the round tubing of the subframe does not aesthetically match the angular shape of the second gen frame. Perhaps if the subrame were made of rectangular tubing it would match better. Maybe you should whip up another one in your spare time so we can compare them. While you're at it, I liked the first one you made out of the sheet metal, except for the round holes. Maybe you can square off and elongate the holes into rectangles and we will see how that looks. :) Just kidding, it looks great, very racy.
 
Some super impressive skills! I actually quite liked the first iteration, though the second is awesome too. No wrong choice if you ask me


Sent from my iPhone using DO THE TON
 
I hate you and your fancy jigs and skills......

Seriously nice fabrication.
 
Haha thanks fellas. I didnt "hate" the first iteration with the aluminum, but it wouldve taken plenty to make it function right, and still possibly not even be any lighter than the stock unit. And I am lucky to have access to things like the fixturing tables, and theres always a good lesson on reverse engineering and measuring with my fabrication classes when a project like this comes along..


For electronics trays, I believe that I am going to go with a shorai lfx14 and make a custom battey box to mount a bit lower beside the rear shock. The original plan was to run a TWF box which reloacated the battery to the right of the front cylinder, below and behind the radiator, but it seems that is usually done for race applications and I would be concerned for that location in "daily riding" situations.

Ill see how good Santa is to me and get a battery on the way.


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Looks pretty good. Going to paint or leave natural?
 
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