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View Full Version : Completed 2001 Suzuki SV650 "Cafe Fighter" Build



c_morse
02-12-2012, 10:35 AM
Migrating this and several other threads over from the site we defected from.

Feel free to share your comments/critiques/questions. I look forward to them!

c_morse
02-12-2012, 10:37 AM
7 November, 2010:


First and foremost, I'm copying this pretty much directly from another site I posted on, so if you see anything talking about "read on this site" or the like, it's referring to svrider.com and not here. Other than that, here we go:

Purchased this bike on 23 October 2010.

Previous owner had done a few things to it. This is the way it sat at time of purchase:

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs460.ash2/73382_1642714229050_1272672326_1751063_7213304_n.j pg

The most notable modifications already to it were as follows:

-All turn signals deleted
-Front stainless brake lines
-CNC Bar-end Mirrors
-Stage 1 Jet Kit
-Desnorkeled intake
-Scorpion Carbon Fiber Slip-On
-Custom made Carbon Fiber Kickstand
-Fender Delete
-Renthal Handlebars

Of course I couldn't wait to start modifying it, as subsequent posts will reveal.

c_morse
02-12-2012, 10:37 AM
7 November, 2010:


First on the list was to get the turn signals back. I want the bike 100% functional, and also like the added security when riding that comes with actually having functioning signals.

Instead of adding in rear signals I found a thread detailing the install of a trailer lighting control that can be picked up from any auto parts store. After picking up the part in town, I came home and broke out my soldering iron, heat shrink, etc. This was the result:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2146.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2147.jpg

Also took the time that day to rearrange my garage a little to fit this new toy in there. Now she's all nestled right in front of my mint 1990 300ZX:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2148.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2149.jpg

c_morse
02-12-2012, 10:38 AM
7 November, 2010:


Now that I had fully functioning turn signals again, it was on to a bit of actual modification. Read about the rideitmoto adjustable levers on this site, so ordered up a set. Got the shorties, and in the gold anodized finish. Very nice units, I must say. No more "carbon look" controls (I can't stand fake carbon). Anyway, a couple pics of the old fake carbon units, and the new ones installed:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2154.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2159.jpg

Also dropped a few bucks on some billet aluminum foot pegs, and a billet aluminum shifter. Will be getting full rearsets hopefully before the end of winter, but these are good enough for the remainder of the riding season:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2155.jpg

The final thing to install was a clear Lockhart Philips brake light. Picked it up for ~$20 off eBay. It'll suffice until I upgrade to a full LED unit.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2157.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2160.jpg

c_morse
02-12-2012, 10:39 AM
7 November, 2010:


Received my DDM Tuning Hi/Lo HID Kit in the mail this week, but held off a bit on installing it. I had some left over wiring I wanted deleted from the harness, and wanted to full integrate the HID kit into the factory harness. So, during the week I began the tear down of the bike. Took a single night to get it ripped apart enough to get the entire wiring harness out:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2162.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2163.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2164.jpg

c_morse
02-12-2012, 10:39 AM
7 November, 2010:


Two nights of tedious labor to include soldering, wire tracing, and re-wrapping the entire harness, I had this what's below. Everything is now integrated, and the turn signals have actual connectors like I'd wanted from the start:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2167.jpg

Also got the HID bulb installed into the headlight housing. Ended up having to extend the HID wires from the bulb by about 10 inches so they'd reach into and connect inside the frame, but more on that in just a minute:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2165.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2166.jpg

I ended up mounting the HID ballast box and ignitor inside the lefthand side of the frame, directly underneath the air box. Here you can see the location, as well as final HID wiring that I came up with. You'll notice the extended bulb wiring that I routed back and into the frame where it connects to the Ignitor:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2168.jpg
http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2169.jpg

c_morse
02-12-2012, 10:40 AM
7 November, 2010:


Took me a few hours of work, but I got the whole bike back together in a single night. Here's the nearly finished result:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2170.jpg

In this picture, you can see the trailer adapter as well as the new HID control box. I chose to mount this in the rear section as it's close to the battery and I also had a ton of room. I routed the High and Low beam wires to this location and deleted the original headlight ground from the front of the harness, while tying a new ground for the HID's into the rear section of the harness:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2171.jpg

This is the pile of wiring/old tape/old zip ties/etc I ended up with at the end of the project:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2172.jpg

First turn of the key/startup and everything works perfect! Not a single bug to work out. Here's the HID in all its glory:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2173.jpg

Also, not pictured is the battery tender wiring harness I installed.

c_morse
02-12-2012, 10:41 AM
19 November, 2010:


Update time again. Here goes.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2177.jpg
Previous owner installed that chrome chain cover. Just not my style. Bought a stock one and replaced.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2178.jpg
Put the stock kickstand back on as well.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2179.jpg
Previous owner had installed this carbon fiber kickstand. It's nice, but hard to kick down and not near as stable. Also stands the bike up too much. Not sure what I'm going to do with it (if anything) yet.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2182.jpg
"New" used K&N Filter. Very nicely desnorkeled. Old filter on the right was very poorly desnorkeled.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2183.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2184.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2185.jpg
And the new K&N in the bike.

c_morse
02-12-2012, 10:41 AM
19 November, 2010:


http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2186.jpg
New headlight bucket arrived. You can see the old one in the picture had a piece of metal riveted to it to hold it together. No good.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2187.jpg
Front end ripped apart for some fun. :D

c_morse
02-12-2012, 10:42 AM
19 November, 2010:


So, I decided to go with clip-ons. Bought a set of Vortex units which are very nice I think. I went with an S Upper Triple to clean things up quite a bit.

I'm planning on adding an Acewell 2853 Gauge down the road a bit, but for now I am keeping the stock cluster. This presented a small problem in that there are no provisions underneath the S upper for the stock naked cluster to mount. Easy enough to fix though with a couple of small aluminum strips and a trip to Lowes for some new hardware.

Here's what I came up with:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2188.jpg
The extension pieces. If anyone is curious, the distance from the naked holes to the holes on the underside of the triple is 1.25". I cut the strips 2" long, and then centered a hole 3/8" from each end. This puts the holes at a nice distance for a good snug fit of the gauge cluster to the new upper triple.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2192.jpg
The parts after a couple coats of primer and paint, and baking to cure.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2193.jpg
How everything looks underneath. I used Allen head bolts with lockwashers to mount into the S upper, the bolt size is M6x1.25x12.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2194.jpg
And how it looks from the top. Not too shabby.

The headlight brackets were the next issue. I'd seen those kits on eBay for $40 shipped that contained four t-bolt clamps sized for 41mm forks, but I'm really not about to pay that for some clamps. So I used my handy dandy measuring tape and came up with a fork size just a hair under 1.5" diameter. A quick visit to www.siliconeintakes.com and I had four 1.5" stainless t-bolt clamps shipped to my door for $16. Definitely a bit better of a deal for the same thing!

Anyway, here's the result:

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2190.jpg
Keep in mind that I'd already modified the headlight brackets to hold my turn signal, so that was a non-issue for me. I did have to use my dremel with a cutoff wheels to shorten the length of the bolts post-install, as I didn't like how long they were sticking out. I turned the triples lock to lock, and the long bolts don't interfere with a thing, so that's just personal preference.

c_morse
02-12-2012, 10:43 AM
19 November, 2010:


Now it was time for the clip-ons. Went with Vortex 7* angle units. Very nice.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2191.jpg
The beginning of it all.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2195.jpg
After getting all the controls on. I installed an R6 throttle tube as well, just didn't think to take a picture of it. Easy enough to do, and the adjustments for the cables were pretty easy.

Also set my bar-end mirrors a little further forward than the previous owner had had them. This should give me a bit easier adjustability than what they had. Definitely needing a set of Driven D3 grips now though.

I am also going to have to order some shorter brake lines, as the ones on there now just have too much slack since I moved the bars about 4" down.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2196.jpg
A view from back toward the riding position. I tried these out, and it's really not near as uncomfy as I'd heard it was going to be. Feels very positive to me.

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2197.jpg
Also took the time today to paint a few items on the bike. The chrome gauge housings are now matte black, as is the headlight housing and chrome trim ring. This looks just so much better to me.

c_morse
02-12-2012, 10:43 AM
19 November, 2010:


Finally, a few shots from around the bike. I'm waiting on my complete lock set to come tomorrow, so I have to wait until then to take a ride. :(

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2198.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2199.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2200.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2201.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2202.jpg

http://i25.photobucket.com/albums/c84/hookduphatch/IMG_2203.jpg

c_morse
02-12-2012, 10:44 AM
9 January, 2011:


http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1380.snc4/163290_1762838952093_1272672326_2015940_5452536_n. jpg
Tank and Plastics removed for paint. Going Matte Black on it all.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs009.ash2/33797_1762839272101_1272672326_2015941_5296677_n.j pg
Next time I take a picture of this tank, it won't have truck bed liner on it.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs795.ash1/168535_1762839432105_1272672326_2015943_6517948_n. jpg
Start of the teardown.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs756.ash1/164752_1762839712112_1272672326_2015945_2006775_n. jpg
Bike as it sits now. You can see the new gold Driven D3 grips I installed as well.

c_morse
02-12-2012, 10:45 AM
12 January, 2011:


Couple of more pictures. Got the bike ripped down some more. Sorry for the fuzziness of the first one.

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs776.ash1/166598_1767584350725_1272672326_2027292_7672459_n. jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs800.ash1/169039_1767584630732_1272672326_2027293_7724891_n. jpg

c_morse
02-12-2012, 10:46 AM
31 January, 2011:


Got a little bit more done. Temporarily installed the ZX6R rear adjustable shock as I sold the stock one. Also got the wiring harness completely removed. Removed the front brake calipers and also the front and rear spark plug wires/coils.

Moving right on along! Here's a shot of it from tonight.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs076.snc6/168650_1797314773967_1272672326_2084202_4057031_n. jpg

c_morse
02-12-2012, 10:46 AM
5 February, 2011:


Got more done.

All controls are off.
Chain is off.
Carbs are off.
All brakes are off.
Exhaust is off.

I need to drain the oil and coolant this weekend, then drop the motor. Once that's done I can finish disassembling the frame/swing arm/forks for powder coating. Getting close to complete break down and should be starting reassembly with fresh parts within a month.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs253.snc6/180131_1806034791962_1272672326_2098909_1051979_n. jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs048.snc6/167869_1806034911965_1272672326_2098910_436417_n.j pg

c_morse
02-12-2012, 10:47 AM
7 February, 2011:


Another awesome day of work. And finally glad to say the bike is completely disassembled. All I have left to do is to modify the subframe and clean it up, then everything can go to powdercoat.

Decided to go with the Lollipop Red on the frame and swingarm, subframe and front forks will be matte black. Triples will be gloss black. All the other small pieces will be going matte black. Brake calipers will be gold. I'm going to try to paint the wheels gunmetal, and if they don't turn out like I want, I'll go ahead and have them powdercoated as well. We'll see how that goes.

Anyway, the pictures:

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs280.snc6/180804_1809191470877_1272672326_2106124_4788328_n. jpg
All the parts strewn through the garage.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs791.ash1/168168_1809191550879_1272672326_2106125_6543723_n. jpg
The wheels perched against the wall.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs290.snc6/181844_1809191710883_1272672326_2106126_3026399_n. jpg
Frame and swingarm, completely stripped and ready for coating.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs276.snc6/180408_1809191870887_1272672326_2106127_4235_n.jpg
You can see all the parts going to powdercoat toward the bottom of the picture with labels on them.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs310.snc6/181803_1809191950889_1272672326_2106128_3800203_n. jpg
Engine hanging out, waiting to go back into the bike.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/hs062.snc6/167263_1809192230896_1272672326_2106129_697667_n.j pg
Massive pile of parts.

c_morse
02-12-2012, 10:48 AM
12 February, 2011:


Got a little more work done. Subframe is now modified and ready for powdercoating.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/182204_1817560720103_1272672326_2121537_561074_n.j pg
Stock subframe.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash1/180911_1817560840106_1272672326_2121538_6023525_n. jpg
All the bits that were removed.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/179889_1817561880132_1272672326_2121546_8025773_n. jpg
Deleted the left side passenger foot peg mount, tie down bars, etc.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/168950_1817561960134_1272672326_2121547_4263672_n. jpg
Deleted the stock rear brake reservoir mount.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181540_1817562120138_1272672326_2121548_6211225_n. jpg
Deleted the rear reservoir hose guide.

And now for some goodies - new parts for the bike!

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash1/181902_1817560960109_1272672326_2121539_53982_n.jp g
Corbin seat.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181686_1817561160114_1272672326_2121540_4607273_n. jpg
Delkevic 200mm Mini Slash-cut Carbon Fiber slip-on Exhaust

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash1/168076_1817561320118_1272672326_2121541_6823733_n. jpg
Acewell 2853 Digital Gauge.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/180155_1817561520123_1272672326_2121542_5800908_n. jpg
New front turn signals. Going to mount them on the sides of the radiator.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash1/168902_1817561600125_1272672326_2121543_4580692_n. jpg
ZX6R Rear Adjustable Shock

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash1/181713_1817561680127_1272672326_2121544_7726510_n. jpg
MDA-123 Li-Po Battery. Less than half the size and weight of the stock battery, with the same voltage and CCA.

That's it for now. All the parts getting black powder are going out this week. Need to order the red powder and get the tires off the wheels, then will send in the other parts.

c_morse
02-12-2012, 10:49 AM
10 March, 2011:


Not much of an update, but I'm still waiting on a lot of stuff and/or the money to get stuff I'm still needing. Received my black parts back from the powder coater the other day. Here's what we've got:

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/183577_1861214571422_1272672326_2199801_6051154_n. jpg
Swingarm and fender delete

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/184823_1861214731426_1272672326_2199802_5886879_n. jpg
Fork legs, braces, triples, kickstand, etc

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/189089_1861214971432_1272672326_2199803_1021330_n. jpg
Subframe, radiator guards, etc.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200743_1861215091435_1272672326_2199804_4830498_n. jpg
Picture of everything just returned from powdercoating.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/198829_1861215331441_1272672326_2199806_828005_n.j pg
Headlight reassembled. Didn't realize the bottom mounting bracket hadn't gone to the powder coater. It's sitting on the table now and will be dropped off Friday. Went with gloss on the trim ring.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/199276_1861215811453_1272672326_2199808_4027630_n. jpg
The beginnings of reassembly on the subframe. Still need to modify the battery box to fit the new battery and clear the new shock.

Anyway, as of today I sent out the frame, wheels, cush drive housing, and front brake discs for powdercoating in the flat anodized red shown above. I'll hopefully have them back next week.

Side note: Anyone know how far one needs to take brake calipers down in order to powdercoat them?

c_morse
02-12-2012, 10:50 AM
11 March, 2011:


Received my new billet integrated rear brake reservoir in the mail today and had to get it bolted up to see what I thought. I reallllllllly like this little piece!

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200070_1864156004956_1272672326_2203462_256588_n.j pg

c_morse
02-12-2012, 10:51 AM
12 March, 2011:


And once again, small progress... but progress nonetheless. Tonight I built the battery box to hold my new MDA123 battery, and also assembled the swingarm as much as possible. Without further wait, some pics:

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200441_1865129389290_1272672326_2204502_4214419_n. jpg
Profiled the right side (in the picture) to match the architecture of the plastic, then sanded smooth. Cut away the floor on two sides, about 2/3 of the way across on the back plate, then made a shallow cut along the floor to facilitate bending it up.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200267_1865129749299_1272672326_2204504_5260084_n. jpg
This is the finished product. I did drill holes after this to later add a zip tie to secure the battery, but you get the idea. I plastic welded the sides and bottom, then sanded most of it smooth, finally using a heat gun to melt and smooth the plastic.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185980_1865129909303_1272672326_2204505_361067_n.j pg
Here's a close up of the side and bottom plastic welds that are holding everything together now.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/199056_1865130149309_1272672326_2204507_3189933_n. jpg
Inside the battery box.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/197366_1865130309313_1272672326_2204508_4566161_n. jpg
And here is underneath.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/197635_1865130509318_1272672326_2204509_474033_n.j pg
Repacked all the bearings on the swingarm, then added the chain guide and also the main bearing caps. Installed the rear spools as well. Finally installed the rear caps and chain adjusters. Swingarm is pretty much ready to install now.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200201_1865130669322_1272672326_2204510_6665527_n. jpg
Picture from the back of the swingarm.

Anyway, I spent several hours on this, and I'm happy with the results. Back on hold until I get some more parts in to work with.

c_morse
02-12-2012, 10:52 AM
20 March, 2011:


Alright,

Got most of my parts back from the powder coater today! The only exception was the front wheel. It pitted and has to be reshot. Was able to start on assembly. Got the rear wheel mostly reassembled, installed the swingarm on the frame, installed the new shock, links, etc... and installed the rear subframe. Got it up on stands at the end of the night. Anyway, some pics!

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196756_1881333714388_1272672326_2228689_5009154_n. jpg
Frame. It's coated in Aussie's Flat Red Anodized, and it looks simply stunning in person!

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200435_1881333994395_1272672326_2228690_7070780_n. jpg
Picture of the frame with flash off.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190481_1881334154399_1272672326_2228691_3484269_n. jpg
Rear wheel... Done the same color.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/200772_1881334394405_1272672326_2228692_8071101_n. jpg
I also asked them to coat the centers of the front rotors the same color. They did... and then some. Going to have to sit down with a razor and remove the powder coat from the inner edges of the friction surface, but that'll be another day!

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/198913_1881334754414_1272672326_2228696_8109776_n. jpg
Bike at the end of the night. Got a little bit together for sure.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190441_1881334954419_1272672326_2228697_1522444_n. jpg
I sat staring at the assembled parts like this for a good little bit. This bike is going to be sexy!

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/190644_1881335114423_1272672326_2228700_1305140_n. jpg
Shock, etc... Installed on the bike.

c_morse
02-12-2012, 10:52 AM
5 April, 2011:


Tank and plastics are back from paint. New matte black finish. Went ahead and installed the new gas cap as well. Excuse the parts being dirty already, it's pollen season in SC.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207351_1921493478357_1272672326_2278104_5767525_n. jpg
http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/206278_1921493798365_1272672326_2278106_6078325_n. jpg

c_morse
02-12-2012, 10:53 AM
8 April, 2011:


Still pretty slow, but did manage to get the tires back on the wheels and the wheels mostly reassembled. Still need the new wheel bearings and also the new sprocket for the rear wheel.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/206755_1927402146070_1272672326_2285292_1288008_n. jpg

c_morse
02-12-2012, 10:53 AM
10 April, 2011:


Another update: Got the engine degreased and cleaned up last night. Primered/painted and installed today! On to the pics:

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/207479_1931237441950_1272672326_2290220_6118973_n. jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/208172_1931237601954_1272672326_2290221_3311711_n. jpg
Motor after being degreased, dried overnight, and then high-heat primered.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216644_1931237801959_1272672326_2290222_5724757_n. jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/205693_1931237921962_1272672326_2290223_2034410_n. jpg
About half of the motor painted with high temp matte black.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215782_1931238041965_1272672326_2290224_3671432_n. jpg
http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/216399_1931238201969_1272672326_2290225_3957974_n. jpg
Finished engine after high temp matte black.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/218179_1931238321972_1272672326_2290226_4984616_n. jpg
Motor, radiator, and overflow installed.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/206335_1931238441975_1272672326_2290227_3130490_n. jpg
Up close view.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/208578_1931238521977_1272672326_2290228_3711526_n. jpg
Up close view of the other side.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/215939_1931238681981_1272672326_2290230_6096470_n. jpg
View from the top.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215374_1931239001989_1272672326_2290231_7017793_n. jpg
Headers heat wrapped.

Tomorrow I will seal and install the headers. Still can't see the end of the tunnel, but I know I'm getting closer!

c_morse
02-12-2012, 10:54 AM
10 April, 2011:


As promised, headers are now done and installed:

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/207156_1932717438949_1272672326_2293588_1745813_n. jpg
Headers after sealing the heat wrap.

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/206448_1932717718956_1272672326_2293590_1176069_n. jpg
Front header back on the bike.

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216239_1932717958962_1272672326_2293591_2755299_n. jpg
Rear header back on the bike.

More to come sooner than later hopefully!

c_morse
02-12-2012, 10:55 AM
25 April, 2011:


Well guys, I might've crashed my other bike last weekend and fractured some vertebra and all, but I'm still getting stuff done on the bike. It's just really easy going right now so as to not hurt the back or be in pain.

That being said, here's another small update. Got the front turn signals mounted up and wired, and also finally got the Delkevic exhaust installed.

On to the pics:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/218185_1966656567406_1272672326_2337521_8219530_n. jpg
Back side of the freshly powdercoated radiator guards after mounting the new LED turn signals and wiring them.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/221802_1966656727410_1272672326_2337522_1492877_n. jpg
Front side of the guards after mounting/wiring the new signals.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/221814_1966656967416_1272672326_2337523_4433071_n. jpg
Wiring after cutting the wires to length/adding connectors/installing and taping the wire loom.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/224670_1966657087419_1272672326_2337524_5052588_n. jpg
One of the LED turn signal/guard combos installed on the radiator.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/224126_1966657327425_1272672326_2337525_5617955_n. jpg
Front shot of the signals/guards installed. These will be equally visible from the sides and rear. Should be very nice!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/224086_1966657727435_1272672326_2337527_7358656_n. jpg
Wiring harness where it now goes. I'm going to have to relocate the two turn signal connectors in the harness, but that should be extremely easy to do as they don't have to move too awfully far.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/215290_1966658167446_1272672326_2337528_4123767_n. jpg
Delkevic 200mm slash-cut carbon fiber exhaust installed on the bike with a new SV Racing Parts black anodized exhaust hanger. Sourced all new stainless hardware to put this all on. Turned out awesome!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/221945_1966658487454_1272672326_2337530_7970684_n. jpg
Top shot of the setup.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/224658_1966658727460_1272672326_2337531_4957945_n. jpg
Shot from the rear. I really like the look of this exhaust!

Anyway, that's it for now. I have all the parts ready and waiting to reassemble the front forks and install them. Went with Racetech .95 springs, Racetech Emulators, Motul 15 weight fork oil, and all new seals. Also got the SV Racing Parts Front Wheel Captive Spacer/Bearing Kit.

New bearings have been installed on both wheels along with the captive spacers on the front, and I also had the cush drive bearings re-packed. I also got all new oil seals and a few other goodies from bikebandit for the forks.

I'll hopefully have the triples/forks/front wheel installed sometime this week. Really just depends on how I feel.

Hope y'all enjoy the little I did get done though!

c_morse
02-12-2012, 10:55 AM
28 April, 2011:


Another small update. Just having to be pretty easy around the house, but was able to get the forks reassembled today. Wasn't that bad on my back, just a little hotter in the garage than I would've liked. Regardless they're done and I'm not hurting much more (if any) for it. On to the pics:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/231191_1973353094815_1272672326_2348989_442783_n.j pg
Fork dampers after I drilled out the original four holes to 5/16" then added an additional two 5/16" holes on them to accommodate the new Racetech emulators. Also took the time to debur all the holes and clean all the shavings out of these.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/225188_1973353294820_1272672326_2348990_5676440_n. jpg
The modified fork dampers along with the new Racetech dampers.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/223221_1973353374822_1272672326_2348991_7087111_n. jpg
Racetech emulator on top of the fork damper in the fork tube.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/221960_1973353654829_1272672326_2348994_7360194_n. jpg
New Racetech .95 kg/mm fork springs and spacer material (before I cut it to length for preload, etc).

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/230500_1973354294845_1272672326_2348998_3774716_n. jpg
Nice little tool I had my roommate make for me. Inner diameter is just slightly larger than the inner fork tube, outer diameter is just slightly smaller than the outer fork tube. It's stainless, and pretty hefty. Was able to use it very effectively as a slide hammer to install the new fork seals, although I did use an old fork seal on top of the new seals to protect them. Didn't take a lot of hits to get the new seals in place at all!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/231181_1973353894835_1272672326_2348995_5808593_n. jpg
Inner and outer fork tubes put back together.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/226070_1973354054839_1272672326_2348996_1506314_n. jpg
Used Motul Expert 15W fork oil, 491 mL worth in each fork.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/215707_1973354174842_1272672326_2348997_7547923_n. jpg
And the finished forks ready to be installed on the bike.

More to come soon!

c_morse
02-12-2012, 10:56 AM
29 April, 2011:


Got a little bit more done with the help of my roommate tonight. Triples got reassembled with their bearings and installed, forks were installed, then the front wheel was installed along with the front fender.

Also picked up a set of Nissin brake calipers and SV Racing Parts Adapter Brackets to install. If the hardware arrives tomorrow, those will go on.

On to the pics!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/225729_1975827556675_1272672326_2353146_48665_n.jp g
Shot of the whole front.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/228206_1975827796681_1272672326_2353148_2705511_n. jpg
Closeup of the left side.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/226820_1975827956685_1272672326_2353149_6869189_n. jpg
Triples. Top is just sitting there for now. No need in bolting it down yet as it has to come back off for a few more things.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/226504_1975828356695_1272672326_2353152_3337108_n. jpg
Right side.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/228729_1975828676703_1272672326_2353154_6364602_n. jpg
New calipers and adapter brackets I picked up.

That's it for now. Should be able to do some light stuff on it tomorrow.

c_morse
02-12-2012, 10:57 AM
5 May, 2011:


Well guys I got bored again and decided to go ahead and get some more done on the bike. That said, I actually did more than I set out to, and I'm starting to really fall in love with the way this thing is looking! Here's some pics of what I got done tonight:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/229114_1988765040104_1272672326_2374341_580996_n.j pg
Picture of the bike with all of the work I did.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/222441_1988765320111_1272672326_2374343_3324918_n. jpg
First things first, got the 4-piston calipers and adapter brackets installed on the bike, then went ahead and routed the braided stainless front lines.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/228578_1988765480115_1272672326_2374344_2944002_n. jpg
Here's a shot of a lot of the stuff I got mounted. I went with Vortex 10 degree clip-on brackets this time, those are completely lined up where I want them and tightened. Also in this picture are the new Aztec8 Headlight mounts. I like that they have a single attachment point on the forks, and they just offer a cleaner install. You can also see the new Acewell 2853 gauge in this picture. It's mounted using some bracketry I came up with under the top triple.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/230910_1988765640119_1272672326_2374345_7683648_n. jpg
Here's a head-on shot. This is looking so clean!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/226310_1988765720121_1272672326_2374346_6637074_n. jpg
This picture details the new gauge, the quick release tank pin set, etc, etc.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/222252_1988765800123_1272672326_2374347_4276420_n. jpg
Here's a little bit out of focus picture looking forward on the bike. Tank is now mounted. Threw the Corbin seat on momentarily just to get a feel for how the bike is going to ride. It's not too bad at all!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/226998_1988765960127_1272672326_2374348_284040_n.j pg
And finally a picture of the other side.

Next up I need to have the carbs cleaned and rejetted and square away all of the wiring changes and get the carbs/wiring harness installed.

Things are slowly but surely coming together!

c_morse
02-12-2012, 10:58 AM
Not much more done, but progress is progress. Here goes:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/230753_2015127539150_1272672326_2411319_8243987_n. jpg
New NGK CR8E plug to the left, replacing the older unit to the right. Gapped to .030

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/230597_2015127739155_1272672326_2411321_4962565_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/228440_2015128019162_1272672326_2411323_1294931_n. jpg
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!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/229592_2015128179166_1272672326_2411325_2413482_n. jpg
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!

c_morse
02-12-2012, 10:59 AM
16 May, 2011:


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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/225019_2016907783655_1272672326_2413714_4525390_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/227321_2016907903658_1272672326_2413715_1782380_n. jpg
Taped off.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/225479_2016907983660_1272672326_2413716_4498323_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/224747_2016908543674_1272672326_2413720_6349102_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/226706_2016908623676_1272672326_2413721_3123301_n. jpg
LED board mounted inside.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/228407_2016908743679_1272672326_2413722_3432287_n. jpg
Connector after soldering on the individual pins and installing.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/230822_2016908863682_1272672326_2413723_1501605_n. jpg
New smoked lens.

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

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/222243_2016908423671_1272672326_2413719_365011_n.j pg

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/228761_2016908343669_1272672326_2413718_8098375_n. jpg

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
02-12-2012, 11:00 AM
17 May, 2011:


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:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/230094_2020999765952_1272672326_2416959_2582691_n. jpg
Dining Room table all set up for the work ahead.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/225418_2020999885955_1272672326_2416960_7227961_n. jpg
Old trailer adapter and light bulb sockets that were coming out of the harness.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/224624_2020999965957_1272672326_2416961_5349413_n. jpg
New, much more compact harness, with the new taillight connector.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/222642_2021000205963_1272672326_2416963_5969395_n. jpg
Wiring all apart and labeled for the new Acewell connectors.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/230182_2021000445969_1272672326_2416964_7757920_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/230331_2021000565972_1272672326_2416965_3581350_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/228036_2021000645974_1272672326_2416966_7656341_n. jpg
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
02-12-2012, 11:01 AM
23 May, 2011:


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:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/230191_2032063042527_1272672326_2429790_1097346_n. jpg
Little aluminum bracket I fashioned to hold the speedo sensor for the new Acewell gauge.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/248714_2032063162530_1272672326_2429791_3442069_n. jpg
Couple coats of primer and a couple coats of my favorite... bumper black, and then baked at 200 degrees to cure everything.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/249357_2032063362535_1272672326_2429792_6325932_n. jpg
The finished product. After figuring out what I wanted, through actually making it, test fitting, etc this one little part took a couple hours.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/225595_2032063442537_1272672326_2429793_7791844_n. jpg
Here it is installed on the bike with the sensor mounted up.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/226469_2032063562540_1272672326_2429794_1468027_n. jpg
Instructions said no more than 8mm clearance from the magnet to the sensor. Think that should do it!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/250746_2032063682543_1272672326_2429795_4220938_n. jpg
You can see the magnet for the pickup mounted in the brake disc.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/225954_2032063762545_1272672326_2429796_4193534_n. jpg
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!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/227139_2032094603316_1272672326_2429874_6401185_n. jpg
Rear plastics installed.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/226541_2032064202556_1272672326_2429799_4130208_n. jpg
Rear brake caliper bracket before paint.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/225269_2032064322559_1272672326_2429800_2063095_n. jpg
Rear brake caliper before paint.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/225462_2032064962575_1272672326_2429804_1058925_n. jpg
Both after matte black high temp brake paint and baking.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/249626_2032064522564_1272672326_2429801_7807481_n. jpg
Rear wheel with cush drive completely reassembled and new 520 47-tooth sprocket installed.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/247168_2032064842572_1272672326_2429803_6083915_n. jpg
New 520 15-tooth front sprocket installed.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/227507_2032065402586_1272672326_2429806_1905827_n. jpg
Finished product. Sooooo close!!!!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/230800_2032065562590_1272672326_2429808_6707252_n. jpg
Other side

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/226989_2032065762595_1272672326_2429809_397350_n.j pg
Rear

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/229265_2032066242607_1272672326_2429813_1942536_n. jpg
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 to be done.

That's pretty much it though!

c_morse
02-12-2012, 11:03 AM
28 July, 2011:


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:

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/223946_2220078942807_1272672326_2634841_5634070_n. jpg
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.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/285058_2220079022809_1272672326_2634842_7938811_n. jpg
More of a side-view of the bike.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc6/285534_2220078742802_1272672326_2634840_7836897_n. jpg
Side shot of the front half of the bike with the new cover installed.

c_morse
02-12-2012, 11:05 AM
2 September, 2011:


Alright guys,

As of tonight, the project is COMPLETE!

Received my Motrax tank pad, SV Racing Parts rear sets, K&N oil filter, and a few other random bits in the mail recently, and finally had a chance to get them all on tonight.

Special thanks goes out to Blair at SV Racing Parts for taking care of me throughout this process. A lot of his parts made it on to this bike, and I'm thoroughly impressed with his customer service, part quality, etc, etc, etc. Really can't say enough good about the guy!

Anyway, pics!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc7/321586_2307882737847_1272672326_2753883_5852264_n. jpg
Shot of the bike running.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/301524_2307882937852_1272672326_2753884_2900418_n. jpg
Rear side shot. I think the bike looks absolutely sinister from this angle.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/311949_2307883137857_1272672326_2753885_2011093_n. jpg
Up close shot of the right side. Of note are the 636 rear shock, Galfer SS brake line, SV Racing Parts rear set, Delkevic mini exhaust, clear clutch cover, and also the CNC fluid reservoir.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/297504_2307883337862_1272672326_2753886_5081419_n. jpg
On top of the tank. Of note are the Motrax tank pad, Acewell gauge (fully functional), and billet gas cap.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc7/298280_2307883537867_1272672326_2753887_7372662_n. jpg
Up close shot of the gauge. Tested fully functional and working exactly as advertised.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/309805_2307883737872_1272672326_2753888_1219199_n. jpg
Front shot showing off the HID headlight. Also of note are the SV Racing Parts caliper adapters and upgraded front brakes.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/303883_2307883897876_1272672326_2753889_4409987_n. jpg
Left side shot, down low.

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/298789_2307884137882_1272672326_2753890_8156074_n. jpg
Shot of the SV Racing Parts left hand side rear set. Nice piece!

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/308036_2307884697896_1272672326_2753893_4081060_n. jpg
And from up and over in the back.


Finally a couple of pics of the SV along with my Daytona 675...

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/314136_2307884897901_1272672326_2753894_1473695_n. jpg

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/295735_2307885017904_1272672326_2753895_3364351_n. jpg


And... a video of the completed project!

http://www.youtube.com/watch?v=H7EuMZrkWCM

c_morse
02-12-2012, 11:06 AM
Final Mods List:

LIGHTING
-DDM Tuning 6000K Hi/Lo Motorcycle HID Kit
-Clear Alternatives Smoked Integrated Taillight
-ELFR-1 Flasher Relay
-Superbright LED Front Turn Signals
-Aztec8 41mm Headlight Mounts
-Replacement Headlight Housing
-Fully integrated HID wiring into the main Harness

BODY
-Targa Solo Seat Cowl
-Stripped/Painted Tins Matte Black
-Powdercoated Triple Clamps Gloss Black
-Powdercoated Headlight Trim Ring Gloss Black
-Powdercoated Frame Aussie’s Flat Anodized Red
-Powdercoated Wheels Aussie’s Flat Anodized Red
-Powdercoated Inner Brake Rotors Aussie’s Flat Anodized Red
-Powdercoated Rear Swingarm Matte Black
-Powdercoated Various Brackets Matte Black
-Powdercoated Lower Forks Matte Black
-Modified/Powdercoated Rear Subframe Matte Black
-Painted Rear Brake Caliper Matte Black
-Motrax Tank Pad
-SV Racing Parts Black Anodized Exhaust Hanger
-Billet Keyless Gas Cap
-99-02 Full Lock Set
-99-02 Black Chain Guard
-Corbin Seat
-OEM Frame Covers
-mrk66 (SVRider) Quick Release Tank Pin Set
-mrk66 (SVRider) Quick Release Panel/Tank Kit
-Nille (SVRider) Black Clutch Cover
-CNC Aluminum Swingarm Spools

SUSPENSION
-Kawasaki ZX6R 03-04 Rear Shock
-Racetech .95 wt Spring/Gold Valve Emulator Kit
-Motul Expert 15W Fork Oil 1 Quart
-SV Racing Parts Captive Front Wheel Spacer/Speedo Delete Kit
-Replacement Rear Wheel Bearings
-SV650S Upper Triple Clamp
-SV Racing Parts Front Nissin Brake Adapter Brackets/Hardware
-Gold 954 Nissin Front Brake Calipers/Galfer Brake Pads

CONTROLS
-Billet Gold Shorty Adjustable Levers
-SV Racing Parts Rear Sets
-Vandriver Rear Integrated Billet Brake Fluid Reservoir
-Yamaha R6 Throttle Tube (5SL-26240-01-00)
-Vortex 41mm 7* Clip-on Handlebars
-Driven D3 Gold Aluminum Grips
-SV650S SS Front Brake Lines
-Galfer SS Rear Brake Line

ELECTRICAL
-MDA123 8 Cell Li-Ion Battery
-Acewell 2853 Digital Gauge
-In-Line Brake Pressure Switch
-FH016 MOSFET Regulator/Rectifier
-D’Ecosse (SVRider) R/R Wiring
-Modified Stock Wiring Harness w/ New Fuel Circuit, Deleted all Unused Wires, Added New Connectors For Rear Brake Light & All Turn Signals, etc

ENGINE/PERFORMANCE
-K&N Desnorkeled Air Filter
-Delkevic Mini - 8” C/F Round Muffler
-OEM Radiator Cap
-K&N Oil Filter
-Heat Wrapped/Sealed Exhaust
-Painted Engine Matte Black
-SV Racing Parts 520 Chain Kit (47T Rear Sprocket)
-NGK CR8E Spark Plugs .030 Gap