'99 SV650 track rebuild

doc_rot

Oh the usual... I bowl, I drive around...
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I picked this bike a year ago. It's definitely seen better days but there are some nice parts on it. Last spring I went through the wheels, brakes, forks, and threw new tires on. Did some track days this summer/fall while somehow riding in the rain each time! This bike has not been overly reliable at the track but nothing failed that kept me from riding after some fiddling about. The wiring is pretty bad, some splices merely held together with tape and prayers. I'm going to do a proper race harness, rebuild the shock and a few other things to ensure its reliability. I decided at that point its not that much more effort to tear it down to it main components and inspect everything since I don't trust whoever maintained this bike previously. The decision to tear it all the way down plus my hatred for the current paint job is going to see me paint and powder-coat a few things. Not going to be a fancy job since if i do anything nice it will probably guarantee that I crash on the first lap next season. I really don't like the silver paint on the frame. should be a pretty simple refresh mostly for some peace of mind and some reliability....Also cool paint job.

Possibly a couple upgrades, adjustable Vortex rear sets, new switches, maybe a slipper clutch?
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Interested in following along. I just picked up a 2nd gen (2004) sv650 that will be my daily mule, but I have contemplated track days. Mid Ohio Sports Car Course is 20 min from my house, and I think it would be a riot.
 
Here is the wiring diagram I used on my last race SV. It is from Zoran at TWF. I just sent my last SV to a buddy, but do have a few 1st gen spares, like radiators, fans, exhausts, subframes, swingarm and a tub of misc. brackets nuts and bolts and such, if anybody needs anything. Some of it can be made to fit the early 2nd Gen with cutting and welding. Let me know if anybody needs anything as it will go cheap.

They just repaved Mid-Ohio, so I am looking forward to see what the new pavement will be like, especially in the rain. In my opinion, that track was unraceable with the pavement the way it was. There was limited traction in the dry and none in the wet.
 

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thanks for the diagram. I might be interested in an exhaust. I have a spare muffler that came with the bike but its heavy and kinda fugly. Got any wheels? I want a spare set for rain tires.
 
thanks for the diagram. I might be interested in an exhaust. I have a spare muffler that came with the bike but its heavy and kinda fugly. Got any wheels? I want a spare set for rain tires.
I don't have any wheels, I used my spares on my FZ600. I have an Akropovic TI muffler and I have a complete Remus stainless race system, The wisdom for 1at gen exhausts is that the M4 you have makes the most power with Micron coming in second. I do have a complete stock system also.
 
Debating the color for the frame. I was thinking maybe a solid dark gray or a dark blue, but I might go basic and just do a satin black.
 

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What about a titanium or graphite type color? Something that fits in-between.
 
I used satin black on my last FZ600 racebike. It looks better than the oem silver frame. I have red bodywork and fairing.
 
heres a couple quick color way mockups.
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I don't have any wheels, I used my spares on my FZ600. I have an Akropovic TI muffler and I have a complete Remus stainless race system, The wisdom for 1at gen exhausts is that the M4 you have makes the most power with Micron coming in second. I do have a complete stock system also.

Ken is one of those wheels you gave me with the fz off of an sv? I think the rear that was on it may be off of one. If it is id be happy to move it on to this project


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Ken is one of those wheels you gave me with the fz off of an sv? I think the rear that was on it may be off of one. If it is id be happy to move it on to this project


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I don'i think so. It may have been off a CBR600F2. I am pretty sure I only had 2 SV wheels that are on my FZ.
 
One of our Arkansas neighbor kids wrecked his SV650. The resulting rebuild was a naked street fighter. He painted or powder coated the frame gloss black with a red tank. Pretty sure the tank was actual paint or powder but the color reminded me of Rustoleum Apple Red spray paint. A few months later the tank was Suzuki dark blue. Both looked good with the black frame.
 
I needed to remove the bearings in the swingarm for powdercoat. The bearings are in good shape and high quality Koyo bearings so I wanted to try and pull them out with out damaging them. I made this thick threaded washer with two flatted sides, pass the washer through the bearing, then reorient it on the back side of the bearing, screw in some all thread with some jam nuts and a socket and the bearings pulled out nice and easy, ill clean the bearings up and reuse them.

I also checked the valve clearences - Its always nice when you check and everything is in spec.

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Rebuilt the M4 muffler. Hammered and dollied out the dents on the can. Fabricated a new end cap in stainless because i couldn't stand the crap welds from someones previous repair. packed with ceramic fiber matt and riveted it back together. I managed to knock it off the bench after I finished it to put a nice little dent in the can.... sigh.

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Flat black and similar colors are so 1999 Red is always faster....:)

I love to save money but needle roller bearings are so cheap, I just replace them. They are available online or at any bearing supply store.
 
OEM replacements were $100 plus shipping. There were two smaller ones for the shock linkage that I didn’t photo graph that have seals on the outside edge.
 
I ended up going with Prismatic Powders "Mystic Lava" on the frame. It has some red and green flake in it and pops in the sun, I'm happy with how it looks. The shock has been rebuilt with a stiffer spring. All the major systems are mostly installed. I'm to the point where i need to start on the custom harness - not my favorite part of any project. As a distraction from that I'm now toying with the idea of a custom sub-frame to move the seat a little higher rather than making a thicker seat.

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