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Introduction

In August 2008 we bought a 2002 SV650N with 4000 miles on it. 
I was looking for an SV to do a GSXR front end conversion on and found this bike on Craigslist. 
The previous owner had had it for about a year and had damaged it soon after buying it. 
He told us he decided to try it out in his driveway and lost control, hitting the curb and bending the stock forks.
He rode it for a year with the bent forks before selling the bike to me. It was the perfect bike for this project.

Contact:  scott9861@gmail.com 

Finished

November 2008
     
         

The Build Up

The K4/K5 GSXR front end was installed using a new upper steering spindle bearing from Zoran and using the stock GSXR lower bearing in the SV bearing race.
The GSXR steering spindle upper bearing seal, jam nuts and washers are used so make sure they're included when you buy your front end because the cost more than $60 to buy separately.






Upper Taper Roller bearing from Zoran.



To start I had to decide what to do with the upper triple clamp. 
I've seen where people have modified the GSXR triple but it looks a little dangerous to drill and mount risers and bars because the casting was not designed to take loads in that direction. 
The thought of pulling away and finding the bars not connected to the bike anymore concerned me so I decided to design a custom triple to be a direct fit for this fork conversion which retains the steering lock, stock instrument panel and bars.
After making all the necessary measurements and designing the model we had the triple made at a local machine shop.

CAD Models:




















    
   
Finished

     


Speedometer Mod

I mounted rare earth magnets into the holders and bolted them into the center of 4 of the rotor rivets. 
I got the magnets and holders from Lee Valley Hardware (www.leevalley.com )
Magnet part number 99K31.01 ($0.24 for 10)
Holder part number 99K32.51 ($0.39 for 10)

I drilled and tapped the holders and bolted them into the rotor rivets with 6-32 x 1/4 long stainless caphead screws.
Update, I just changed the screws to 6-32 flatheads because the hole size in the rotor rivet varies and I wasn't confident that the caphead screws were secure enough. I'll post a sectioned drawing soon.

The sensor is a Cherry GS100701 (Same part as the Digikey item) hall effect switch from a local distributor called Master Distributors (Santa Clara, CA) but they have distributors everywhere.

I machined the bracket out of aluminum, bolted it to the fender mount tabs and drilled and tapped 2 holes with a 6-32 thread through the fender mount tab to allow the bracket to stay in pace when the fender bolts were removed.

The sensor gap to the magnets is 5mm. I originally had the gap set at about 1mm but the sensor was not able to switch to a low state before the next magnet was passing so the speedo didn't read correctly. With the 70 profile front tire the reading is closer to the actual speed than the original setup. 


     






Fender Eliminator

I originally intended to use the plate from http://homepage.ntlworld.com/junej.hendry/scottishsv650site/fendermodtemplate.htm  but when I'd stripped the back end down I decided I could make the plate smaller and retain more of the stock mudguard.

Sorry for the crappy picture but I have not had time to draw it properly and have only photocopied the actual plate. 
But basically it's a cut down version of the plate shown in the link above.

I cut the rear of the fender just behind the hook for the tool bag. The 2 tabs on the plate then slide into the inside of the fender either side of the hook where I drilled and bolted it.

I relocated the CDI box just forward of the tool bag location.

I'm using a rear lamp unit with integrated turn signals so there's no need to mount external signals.





















Rear Shock

I installed an 05 Kawasaki ZX6R Shock

It was a straight swap apart from a small cutout in the battery box and a slight relocation for the battery.

I've shown a red line where I removed the material from the battery box.




Battery Relocation and clamp



Finished

Here it is !!















ALL THE INFORMATION BELOW IS RELATED TO MY 04 SVS PROJECT.



This image is related to installing a shorter 06GSXR shock on an 04 SV.





Temperature plot of warming cycle of an 04 SV650S that I was having overheating problems with.

Note: Temperature spike at 650s was due to bleeding air from the cooling system.

Conclusion: At 1177s the temp suddenly rose at Rad out but was not much higher at rad in. At 1273s the fan cam on and went off again at 1297.  But the average temp at Rad out was still rising. For some reason the radiator stopped being able to cool as efficiently. Maybe air getting into the cooling circuit and causing the coolant flow to reduce ?

Please email me if you have any alternative conclusions.




























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Graeme S,
Aug 4, 2009, 10:23 AM
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Graeme S,
Dec 14, 2008, 2:36 PM
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Graeme S,
Dec 14, 2008, 2:36 PM
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Graeme S,
Dec 14, 2008, 2:36 PM
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Graeme S,
Dec 14, 2008, 2:37 PM
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Graeme S,
Dec 14, 2008, 2:35 PM
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Graeme S,
Dec 14, 2008, 2:35 PM
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Graeme S,
Dec 14, 2008, 2:37 PM
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Graeme S,
Dec 14, 2008, 2:37 PM
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Graeme S,
Dec 14, 2008, 2:37 PM
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