Wanted to share another of my passions - Project SV650 "Cafe Fighter"

[slowGEEZR]

Lookin' good! I love to ride 'em, hate to work on 'em. Liked the suspension mods, should improve the handling quite nicely! Funny, you really lowered the grips, while I raised mine on the Duc, left them standard on the R6. Keep it, ought to be a great ride!

 

[c_morse]

Not much more done, but progress is progress. Here goes:

New NGK CR8E plug to the left, replacing the older unit to the right. Gapped to .030

Picture is a little deceptive in that there's a lot more done that it looks like. Got the wiring for the starter put back in, also the engine ground. Also cleaned up and installed the coils/wires/spark plugs.

FH016 MOSFET R/R from a Kawasaki 636, as recommended by D'Ecosse. This sucker went from South Carolina to California and back in a week! Received D'Ecosse's wiring mod from the man himself!

R/R mounted. wiring hooked up to the stator harness. Left the positive and negative wires loose until the battery goes in and I figure that out.

Anyway, received my wiring diagram today from D'Ecosse. Making a run into town tomorrow to get my supplies I need to do the fuel circuit for the gauge. If the brake light comes tomorrow, I'll get started on modifying the wiring harness.

Goal is to have the harness done by Tuesday night, hopefully install Wednesday. I will also be able to get all the tail plastics installed for good.

Sprockets and chain should also be here this week, which means the back wheel can also finally go on and I can see chain slack and get everything locked down.

I also have the supplies to get the rear brake caliper painted this week. Hopefully y'all will see some larger updates toward the weekend!

 

[Wardsweb]

Wow that's a lot of work but I sure it is a labor of love. It looks fantastic so far. I can't wait to see the finished product. I know you wan't wait to hit a few curves with it.

 

[c_morse]

Unfortunately thanks to my motorcycle accident and fractured back, I have to wait, haha! 3 months, doctor's orders.

Lord knows I'll be sitting there imagining though.

Thanks for the compliment!

 

[Wardsweb]

After my back surgery, I sold my Suzuki "Busa", Kawasaki turbo/nitro KZ and Susuki GS1500E. Alas no more riding for me even 10 years later.

 

[c_morse]

Sounds like your bikes were definitely a little faster than any of mine.

I had thoughts of selling for about 10 minutes, then it bit me again.

 

[Wardsweb]

The Busa was wicked fast and stable approaching 200mph. The KZ was a straight line drag bike running almost 30 pounds of boost. The GS was the last of the none faring muscle bikes. The kicker is I wasn't injured riding. I got hurt at work.

Enjoy yours, it is turing out really nice.

 

[slowGEEZR]

Unfortunately thanks to my motorcycle accident and fractured back, I have to wait, haha! 3 months, doctor's orders.

Lord knows I'll be sitting there imagining though.

Thanks for the compliment!

Ha ha, I know what that's like! I wasn't supposed to ride when I had a bad crash back in 2002, but somehow I managed to pull/stretch my left arm out enough to reach the handgrip and rode anyway. I shudder to think now what would have happened if I had wrecked again with those injuries not healed.

 

[c_morse]

Well had to run all day to take care of some stuff with the motorcycle that I crashed. That's all done. On a positive note, was able to gather all the supplies I need to modify the fuel sensor circuit and also redo the wiring harness. Got home and felt like I needed to do at least a little something, then I noticed my brake light housing came (why the Clear Alternatives kit is just a kit and not an entire unit is beyond me). Decided to go ahead and get the brake light completely done.

Here it is after cleaning up and masking off the areas I didn't want painted. Really a piece of crap, especially the lense. Luckily I just needed the body.

Taped off.

After a couple of coats of self-etching primer. The lens was bad off, so decided to sacrifice it instead of having to tape off the shiny inner housing.

Finished unit on the right. Couple of coats of "bumper black" and baked at 200 degrees in the oven to cure it. Also the new Clear Alternatives integrated LED kit and the connector I decided to use.

LED board mounted inside.

 

[c_morse]

Connector after soldering on the individual pins and installing.

New smoked lens.

Also got some more goodies. SV Racing Parts 520 chain kit arrived! Went with a 15/47 tooth setup.

Going to try to get the wiring harness mostly if not all the way in order tomorrow, but I'm expecting it to run into Wednesday. No rush at this point anyway.

 

[c_morse]

Alright.

Wiring harness is done! I varied a tad from TamSV's method, but still both are pretty much the same. I'll post what I did at the end. First the pics:

Dining Room table all set up for the work ahead.

Old trailer adapter and light bulb sockets that were coming out of the harness.

New, much more compact harness, with the new taillight connector.

Wiring all apart and labeled for the new Acewell connectors.

Finished product with new Acewell connectors. Also deleted several wires all the way back in the harness that were no longer needed. Namely illumination, Fuel Level B, and Ignition Signal.

 

[c_morse]

Here's the new fuel gauge circuit. Several resistors are included in that wiring bundle. I left the ends exposed and with actual sockets in case I need to swap the 10 and 100 ohm connections on the relay.

And here's the pile of crap I was left with afterward.

Okay, on to the wiring I employed, and what it does.

*THIS IS ONLY FOR A FIRST GEN NAKED*

Format will be gauge function -> bike function (if different) / gauge wire color -> bike wire color. If two colors it'll be "primary color/stripe"

Ground / Black -> Black/White
Clock Power -> Constant 12V / Brown -> Red
Switch Key -> Switched 12V / Red -> Orange/Green
Fuel Level -> Fuel Level A / Blue -> Red/Black (Keep in mind for the fuel circuit I chose to use the Red/Black wire from the tank)

Left Turn Signal / Orange -> Black
High Beam / Light Green -> Yellow
Caution -> Water Temp Warning / Light Blue -> Black/Green
Neutral / Purple -> Blue/Black
Oil Level Warning / Gray -> Black/Blue
Right Turn Signal / White -> Light Green

I chose to use the stock bike wiring as it seemed to be pretty beefy, and I got rid of most of the original grounds on the main wire anyway. If it seems to be a problem, I'll go directly to the battery.

Anyway, tomorrow I should get the harness and the carbs in the bike, and then I can put all the tail pieces on. I'll finish out the week putting the rear wheel on with the new sprockets and chain!

 

[c_morse]

And now... for a MEGA UPDATE!!! Here is the culmination of a couple days (Friday and today) of work! Basically done except for the rear sets and rear brake line I need to order!

Pics:

Little aluminum bracket I fashioned to hold the speedo sensor for the new Acewell gauge.

Couple coats of primer and a couple coats of my favorite... bumper black, and then baked at 200 degrees to cure everything.

The finished product. After figuring out what I wanted, through actually making it, test fitting, etc this one little part took a couple hours.

Here it is installed on the bike with the sensor mounted up.

Instructions said no more than 8mm clearance from the magnet to the sensor. Think that should do it!

 

[c_morse]

You can see the magnet for the pickup mounted in the brake disc.

Wiring harness installed, carbs installed, airbox put in, everything plumbed.

I tried out the wiring to make sure everything worked. The wiring that D'Ecosse gave me for the fuel gauge works great, but the 10 ohm and 100 ohm resistors on 87 and 87a of the relay were backwards on the diagram as he warned they might be. Took care of that and works as advertised!

Rear plastics installed.

Rear brake caliper bracket before paint.

Rear brake caliper before paint.

 

[c_morse]

Both after matte black high temp brake paint and baking.

Rear wheel with cush drive completely reassembled and new 520 47-tooth sprocket installed.

New 520 15-tooth front sprocket installed.

 

[c_morse]

Finished product. Sooooo close!!!!

Other side

Rear

Front

As of now, I need to order a tank pad along with Tech Spec grip pads for the tank, SV Racing Parts Rearsets, and a Galfer SS Rear Brake Line.

I am trying to find a rivet tool so I can rivet the master link onto the chain.

I am still waiting on the clear clutch cover to come from Germany.

I need to send the top triple out to be re-powercoated, and I need to paint the body of the lock cylinder black.

I need a couple little odds and ends, then fluids and a new oil filter.

Rear shock also realllllly needs to be set up still, and the gauge still has a couple of settings I need to install.

That's pretty much it though!

 

[slowGEEZR]

Looks awesome! Great job! I rode about 240 miles today, in this Texas heat, then jumped in the pool. Now off to go listen to some live music. Life is good.

 

[c_morse]

Life sounds amazing! You're having a lot more fun that I am right now. Haha.

 

[c_morse]

Well guys and gals, I've been slacking a lot with this bike in the last couple months. I got my new Daytona 675 to replace the one I wrecked, and shifted a lot of effort into getting that one up to spec.

The really sad part is that the only major purchase left to be made for this bike is the rearsets! I'm hoping I'll get those on the way within a month or so.

Anyway, parts are still trickling in for the bike. I finally received the clear clutch cover that I've been waiting on out of Germany for about three and a half months. At $300 it was an expensive mod, but it is COOL! It was worth the wait as you can definitely see the quality that went into machining and anodizing/etc. Fitment was spot on and install was extremely straight-forward. I'm very happy!

Anyway, a few pics:

The clutch cover installed. Torqued all the bolts down to 12 ft. lbs. Seems to be plenty. Going to order a gold anodized oil cap to go with this.

More of a side-view of the bike.

Side shot of the front half of the bike with the new cover installed.

 

[JordanD]

Well I dont ride Motorcycles, but I do ride Track bikes a lot haha. I love my bike and I dont ride on a track at all, I just jet around town really quickly, but the cool thing is you when with the same color scheme on your bike as I did, red and black! So kudos for that!