SV650 Adventure (AKA franken bike)

Discussion in 'Some Assembly Required' started by elgato gordo, May 28, 2012.

  1. BlueLghtning

    BlueLghtning Riding is my passion

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    I don't know the specs off hand, but I can tell you that the 07-11 DL650 swingarm is 10mm longer than the 04-06 DL650 swingarm to accommodate ABS if that helps you at all.
    #21
  2. doxiedog

    doxiedog Been here awhile

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    Shorter dog bones,will lift the rear some.
    #22
  3. elgato gordo

    elgato gordo KTMRFS

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    I agree the SV is really cheap, I've see several at auction sites. Parts are plentiful on FleaBay also. The seat height is still OK even with the YZ forks and GSX shock. Great bike you ave there how do the tires do off-road? I'm looking at Shinko 244 or 700 right now. I like those crash bars, that's up pretty close to the top of the "what's next list".


    pjm204
    The motor is just like two KTM cylinders and one KTM gearbox. Only hard part was the special bearing tools that none of my local shops had. Once I made a bearing tool and a flywheel holder the work was pretty easy. I was worried about timing of the front and rear cylinders but it all worked out. Drove around the yard a couple of time tonight and it sounds pretty good.
    #23
  4. RedRaptor22

    RedRaptor22 Been here awhile

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    I don't know if your going to want to use the 244's gordo, they are great tires even though they are shinko's, but I just tore through a rear on the Xr650 in about 1000 miles and it has no power compared to my Sv, plus they are rather soft and flemsy.


    I did find one thing stamped into the sidewall that I thought was kinda funny, "DO NOT EXCEED 70MPH"....I went well over that on gravel with them lol.

    You may want to check out the 700 I think it is, whichever is between the 244 and 705.



    As far as the swingarm, I've been looking at them on ebay and it appears they do have the offset shock, the bearings are the same part number as well, but the spacers and swinger bolt are different part numbers, could'nt find any dimensions on them though, maybe someone will be kind enough to measure their strom swinger width and pivot bolt diameter for you.
    #24
  5. sailah

    sailah Lampin' it

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    If the swingarm doesnt go through the motor which it didn't appear to, a ktm exc swingarm like on my cbr project might be a better way to go. They will definitely fit between the frame and you are all set for running a 18"dirt wheel. You can then fit in an upper shock mount with the pds wp shock and eliminate the linkage. Judging by your fab skills should be easy enough. Longer travel set for dirt and a better travel to match your front travel.

    I have all the parts and can take measurements if you want them.

    I just checked, the swingarm is 24.5" from the center of the pivot bolt to the center of the axle with the adjuster about halfway or maybe 25.5" in total length from pivot to pivot. The swingarm is about 8.5" in width as close as I can measure at the pivot. You'll need to machine a spacer in the middle as they are designed to span an ktm engine. I also had to cut spacers to locate the swingarm in the honda cbr frame. I'm not sure (and can't measure right now) the pivot bolt diameter, but I measured the old honda swingarm and it's a 17mm bore and I don't recall having to sleeve the ktm so I ASSUME the ktm uses a 17mm pivot bolt.

    The issues I ran into are:

    The CBR motor is wider than the KTM obviously so I have to turn down the SC sprocket to bring the chain closer to the motor, and also made a sprocket spacer to kick the chain out on the wheel end. I got damn near perfect alignment. I would expect your SV would be easier and narrower than the CBR being a 4 cyl.

    You'll need to fab up a mount for the upper shock. But you eliminate linkage, the PDS shock works great, easy to get springs for your weight, tons of travel, and the new swingarm should stretch your wheelbase out to a more manageable length than the stocker.

    Hope I explained this well, there's pics in my build thread if you want to see how I did it.
    #25
  6. LukasM

    LukasM Long timer

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    I can add some info to what Peter said if you want to go this way:

    00-03 EXC/SX used a 15mm swingarm axle, 04+ is 17mm.

    It doesn't have to be from an EXC, those from an SX(F), XC(F) etc will all work as they are the same castings (for each year), the only difference is the inner width where the engine normally goes but that should matter anyway if it gets replaced by a spacer.
    #26
  7. elgato gordo

    elgato gordo KTMRFS

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    My main issue with the KTM S.A. is changing the top sock mount since the frame is cast alum and it would require major re-design. The STROM S.A. may be OK but I can't believe it is a big improvement. If I go longer I think a slide in machined block into the existing would be easy and very strong. I would have to move the axles at least 2 to 3 inches to get aft of the existing cut out for the axle. If I get really wild and crazy I may look into re-design of the link system. The fabrication would be pretty straight forward but the layout could be a lot of hours and require several iterations.

    Took a short ride this week on the pavement and I am suprised that is still handles well in the turns with the new geometry.

    Just got the new A model throttle housing so I can route the cables properly.

    Also have a new YZ fender that will fit up high with just a special bracket to allow it to clear the radiator. That's the project for this weekend.
    #27
  8. elgato gordo

    elgato gordo KTMRFS

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    Pretty much the basic stuff done, at least enough to ride. The throttle cables and housing are a bust since the connector on the one I purchased was an 8 pin and mine is a 10 pin. Funny thing the wiring diagram I downloaded show 10 pin to be 2007 and up, mine is 2005. Also the A model cables are about 1 inch longer, so not that great. So I routed the existing cables the best I could moved the grips inboard as much as possible. Really hate the integrated throttle and switch housing. Looks like you can buy it for about $85 or so. All of the stuff on Fleabay is older. This should work OK.

    New cable routing:
    [​IMG]

    Made a special fender mount to allow it to clear the radiator:
    [​IMG]
    [​IMG]
    [​IMG]

    Ready to rock:
    [​IMG]
    [​IMG]


    List of future stuff:
    Hi tech lithium battery because of the GSX shock
    Steering stop
    Tires-Shink 244 or 700?
    Headlight
    Skid plate/crash bars
    Relocate foot pegs and levers
    Slip-on muffler
    #28
  9. RedRaptor22

    RedRaptor22 Been here awhile

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    Oh jesus! that fender! You should look into a vented acerbis two peice motard fender like I have on my Xr lol, doubt you will notice much with the amount of rake you have but I know my stock fender was about that size and on the highway up around 60mph+ it went to flopping back and forth pretty good, which traveled straight to the bars and tire lol.

    Like doxie said you could simply buy dogbones to level it out if thats all you want to do, I had mine lifted an inch in the rear with a set of bones from Svracingparts.com, but I would'nt go more than that without going with dirtbike style chain tension and a few spare chain sliders because even just an inch changed the swingarm angle enough that the slack to tight variance was on the verge of being unacceptable, plus the extra angle on the swinger changed the rear trail enough to force me to buy a better shock because the first two inches of travel were way stiffer than the last two and a half.

    Thats why I reccomend a new swinger, or at least extensions, that way you can get the added travel and not kill your rear rake and trail and the resulting chain path will not destroy chain sliders and possibly force you to install a chain roller.

    A heavier spring will probably be needed but maybe not if your going for dirtbike soft feel, I have a shock from i think an 05-06 gsxr 600/750 that will bolt up, but it'll need a lighter spring and it'll lower ride height by about 10mm.
    #29
  10. elgato gordo

    elgato gordo KTMRFS

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    THe fender is "large" but tested at speeds up to 75 and not too floopy. I think it all looks strange because of the tiny tire but geometry is pretty close to standard dirt bike that would be about 63 degrees rake.

    At the current swingarm angle it would have enough clearance to do 8 inches of travel if I could get a shock that had 90-100 mm of stoke. Seems like that would be Ok for moderate 2-track stuff. I have the GSX 750 1998 on there now. Seems a little stiff but not enough time yet. I have a shock from an SV1000 if I need stiffer spring but would nave to make new dog-bones to adjust the length. These shocks have very little stroke before they hit the bumper. Most shock stroke specs I've seen refer to total stoke if the bumper was not there.

    I can fab some new links for the suspension when I nail down the front end a little more. Pretty happy so far, thought I would have to limit the travel and beef the springs. They are way better that the stock ones, and no clunking either.

    Specs are acceptable:
    Rake = 62
    Ground clearance = 9
    Seat height = 34

    #30
  11. elgato gordo

    elgato gordo KTMRFS

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    Pretty hot for riding around here so got some work done on the SV after a short ride to the Crest to try out the twisty turns.

    First put some new Shinko 705's on order. The 244 and 700 was only available in 5.1 inch wide and I thought the rear rim would be too wide.

    Rebuilt the front forks and put on some new fork protectors.
    [​IMG]

    Made a new spcer for the front axle cause the fist one was too loose. Still kind of hard to put the wheel on since the spacer slips so I put some silicone sealer on it to hold it into the fork clamps.
    [​IMG]

    This shot shows the custom nut I made to adapt the SV axle to the YZ forks.
    [​IMG]

    Started laying out a skid plate.
    [​IMG]
    [​IMG]
    #31
  12. elgato gordo

    elgato gordo KTMRFS

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    Due to the GSX shock upgrade I could not fit the stock battery so purchased a SHORAI lithium ion. Really great product 210 cranking amps, much smaller and only weights about 2lbs. It even comes with special foam packing so you can pad the space as needed.

    [​IMG]
    #32
  13. DaBit

    DaBit Been here awhile

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    How are you going to mount the skid plate to the bike? I used a steel frame from the rear engine mounting location to the 10mm through-hole at the bottom-front of the engine. The steel frame doubles as the mounting point for the pegs and bottom of the vertical radiators.

    [​IMG]

    [​IMG]

    Currently I am not working on that bike but doing some composite experiments for the LC8 instead. That does fit in the big SV-picture though; I am trying to gain enough experience with composite to be able to replace the entire subframe with a composite fuel tank. Battery and regulator will be moved to the skidplate under the engine, and when they are gone the rear of the bike only has to carry me and the tail light. So that's why I think I can leave the classic subframe for what it is and replace it with just a tank.
    #33
  14. elgato gordo

    elgato gordo KTMRFS

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    I'm going to use the kick stand bolt and bolt thru the engine that is not used, near the center. Seemed like getting a longer engine mount bolt would be hard. Ten I'll fab some bars off the forward frame mount to grab the front near the exhaust pipe. Saw one design on the web that used the exhaust pipe bolts on the front cylinder but I don't want to stress that area really.
    #34
  15. RedRaptor22

    RedRaptor22 Been here awhile

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    Get with Blair at Svracingparts.com, he should be able to make you up some longer engine bolts for a not rediculous price, or the guys over at motosliders, they make longer ones for the sliders they make which are widely known to be the best sliders around for the Sv.
    #35
  16. elgato gordo

    elgato gordo KTMRFS

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    I'll give them a call thanks for the info.
    #36
  17. DaBit

    DaBit Been here awhile

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    I used a piece of M10 strength 8.8 allthread. Fixed an M10 nut to the end using two small blobs of weld metal, so it is a bolt now :)

    I wouldn't do that either. Those lugs are not exactly sturdy.
    #37
  18. elgato gordo

    elgato gordo KTMRFS

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    Some important progress this weekend. Starting to look like a motorcycle.

    New skid plate:

    1/8 inch 5052 alum plate
    [​IMG]


    Picked the easy mounts. Will add a front crash bar next to support the front better.
    [​IMG]

    [​IMG]

    [​IMG]



    New tires, Shinko 705. Took a short spin down my road for a test drive. Pretty solid feeling on gravel and some dry ruts, much better than the street tires:

    150x70R
    [​IMG]

    120x90H
    [​IMG]

    [​IMG]

    Next up is the headlight and and extending the kickstand.
    #38
  19. DaBit

    DaBit Been here awhile

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    :thumb

    Looking good!
    #39
  20. elgato gordo

    elgato gordo KTMRFS

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    Couple of mods this week:

    Extended the kickstand:
    [​IMG]

    [​IMG]

    [​IMG]

    Replaced one Fleabay lights with another Fleabay purchase (Hella 1500's). Guess there is some extra room for more but this will do for any day trips:
    [​IMG]

    Took a test ride on some dirt roads north of the Sandia Mts. Really happy with the tires so far they feel good on the gravel. Thought about doing some sand but no one around to help pull me out.

    First up Sandia Crest for some twisties then down the back way thru Placitas.
    [​IMG]

    [​IMG]

    Then out to Hollywood Casino and behind the race track:
    [​IMG]

    [​IMG]

    And Back on Hiway 14
    [​IMG]
    #40