Suzuki SV650S ?

[gromit]

Does anyone have any experience of the SV650 ?

Going to look at one later in the week from a deceased estate. 1998 so very early one with carbs, 44,000 on the clock.
Not running, suspected stale fuel plus carbys need cleaning, runs on starting fluid apparently.

Reading up on the model it's listed in some places as an ideal beginners bike but others use them on track days ?!
Read one report where they were called a 'poor man's Ducati'. My last bike purchased in the UK was a 900SS and this Suzuki is almost the same colour red.

It's cheap and will go on Club Permit but I was surprised at the cost of motorcycle tyres (I'm out of touch).
I'd also need a stack hat as I don't think my UK one meets local regs. It's an old Everoak fibreglass helmet, ACU approved but I don't think that cuts the mustard here......

Colin

[Pedro_The_Swift]

:ttiwwp:

[p38arover]

Not the SV but the DL650. Same engine but mine was a 2007 with fuel injection.

[Saitch]

I just had a chat with my brother, who is reasonably versed in two-wheel pursuits and he remembers the SV650 as a reliable, but somewhat staid, motorcycle. Detuned, perhaps? It was 'Ducati-esque' in appearance, with the full fairing and had a reasonable rumble to the exhaust. Good torque, but nowhere near the Kwakas of the time, performance. (Probably handled better, though.[smilebigeye])



He also added that some Suzis of that era had minor electrical issues.

He also added "If he finds the price of tyres nowadays, a bit steep, wait until he looks at helmets!":spudnikdizzy:

[gromit]

I just had a chat with my brother, who is reasonably versed in two-wheel pursuits and he remembers the SV650 as a reliable, but somewhat staid, motorcycle. Detuned, perhaps? It was 'Ducati-esque' in appearance, with the full fairing and had a reasonable rumble to the exhaust. Good torque, but nowhere near the Kwakas of the time, performance. (Probably handled better, though.[smilebigeye])



He also added that some Suzis of that era had minor electrical issues.

He also added "If he finds the price of tyres nowadays, a bit steep, wait until he looks at helmets!":spudnikdizzy:

Thanks, already had a shock looking at helmets !

Got the SV650, it needs some work as it's been standing for some time and I don't think it had been serviced for years.
Brake fluid was the colour of mud, coolant was very weak and crusty deposits around the cap.
Screen damaged and covered in micro cracks (ordered one from China).
Front indicators need to be replaced, rubber mounts decomposing.
Chain rusty but not worn, will remove clean & lubricate once I get some paddock stands.
Gear lever broken, was knocked over while they think someone was trying to steal it from the back garden !
Tyres date from 2011 so once I have it running I'll replace them.
Carby overhaul kits ordered, I haven't tried starting it.
Purchased oil filter, plugs & air filter.
I'll check brake pads, change fork oil etc.

Light corrosion on most aluminium parts but it only cost $800 and will go straight onto Club Permit.

Electrical issues seem to be regulators failing, common to a lot of Japanese bikes of the era.

Listed as one of the most modifiable bikes ever, now in the 25th year of production. Suspension very average, most people changed/upgraded the forks & rear suspension.
3.6s 0-60mph. Standing 1/4mile 11.85s (back in the day when it was new !).

It came with a Murphys Moto Skate https://www.youtube.com/watch?v=hupbYSHIjpc
I've been offered the previous owners helmet, a Shoei that cost $1K. Never sure about secondhand helmets though.

Once the carby kits arrive I'll strip & clean them, several YouTube videos so common issue with jets gumming up.
Also a lot of articles about re-jetting them.

The aim is to either get back into bikes and restore a couple I brought out from the UK or.....sell them all.

Colin

[gofish]

Looks good. Bullet proof engines

[gromit]

As mentioned elsewhere I ordered a gearlever to replace the broken one.
Turned up and I tried to fit it and found the female thread in the angle ball joint was right hand thread rather than the correct left hand thread !!
Checked the listing and it mentions suitable for RH thread ?! So not actually fit for purpose as the bike needs LH thread !

M6 angle ball joint ordered from Ebay but drilling the original one out will be 'fun'.

The rear brake pedal was sluggish returning, I was getting ready to order a master cylinder seal kit when I decided to strip the footrest/pedal assembly.
Congealed grease & dirt was the problem, a quick degrease & lube and the pedal now returns instantly.

After Christmas the other spares should arrive.
Front indicators.
Carby overhaul kits.
Screen.

I found that some parts are cheaper from a shop (Peter Stevens) rather than buying from Ebay. Air & oil filters for example.
Sparkplugs on special at Autobarn.
Oil I had to hunt around to get a decent price, tried the Penrite helpline to find whether there was a car oil that was suitable (for some reason the word 'Motorcycle' on the container makes it more expensive). Didn't get a particularly helpful reply so ended up with a motorcycle oil that was on special at Autobarn. Some of you are probably aware that you have to be careful with oils used in a wet clutch application.
I remember in the dim & distant past I ran a number of Lambrettas, the gear oil is shared with the clutch. There was always some clown who used EP90 and ended up with permanent clutch slip. I still have some ST90 oil somewhere and a few Lambretta nuts, bolts & cables.

Paddock stands arrived and are assembled so I can remove the rear wheel, check the brakes & clean the chain.
I come from an era when we had to remove & clean the chain then boil up in a tin of special grease (I think I still have some somewhere). This was before O-ring or X-ring chains.
6 years on bikes before I took my car test in the UK meant I was always cleaning & lubing chains.

There's a few large button head shouldered screws missing. I'll have to find alternatives or make up spacers to create the 'shoulder' and washers to increase the head size.

I'm sure I'll find a few more things to fix as I investigate further.......


Colin

[gromit]

Carby overhaul kits arrived from China via Alibaba, very quick delivery.

Removed the tank and removed the carbys, that lovely smell of very stale fuel.
Picture attached of one of the needles.
Overhaul kits fitted, one minor issue that I'll have to think about but all back together for a test tomorrow.

While the tank was off I replaced the spark plugs, the front one was painful to get to. I should have done it while I was draining & flushing the radiator !
The radiator has to be unbolted and there is just enough room, with a few socket adaptors, to get to the plug.

Colin

[Saitch]

Carby overhaul kits arrived from China via Alibaba, very quick delivery.

Removed the tank and removed the carbys, that lovely smell of very stale fuel.
Picture attached of one of the needles.
Overhaul kits fitted, one minor issue that I'll have to think about but all back together for a test tomorrow.

While the tank was off I replaced the spark plugs, the front one was painful to get to. I should have done it while I was draining & flushing the radiator !
The radiator has to be unbolted and there is just enough room, with a few socket adaptors, to get to the plug.

Colin

Good to see it's only minor things, at the moment. On a side note, I was thinking of getting an Asian, carby kit for a 9hp Honda, water blaster motor. What are your thoughts on the product? Thanks.

[gromit]

Good to see it's only minor things, at the moment. On a side note, I was thinking of getting an Asian, carby kit for a 9hp Honda, water blaster motor. What are your thoughts on the product? Thanks.

The needles were incorrect otherwise everything else was OK.
Multiple sellers on Ebay, chose the Alibaba seller because diaphragms included in the kit.

Filled the float bowls and it started and ran for a while then, slowly died.
Fuel pump removed and taken apart, the rubber non-return valves were gummed closed !
Re-fitted, filled the bowls again.

Started & ran OK for quite a while until a fuel leak from the rear carburettor.....looks like I'm taking them off again !
Sounded a bit tappety so I may be investigating valve clearances once I have it working.

Colin

[discorevy]

Hi Gromit, did the kits come with new needles and seats?, I'd think after sitting for a while there'd still be a fair bit of crap and perhaps even rust in the tank, a couple of cheap filters between tank and carbs can save some headaches

I had a Vstrom 650 in the past that was ok ( same donk ) and did the job of bashing up gravel roads and highways reliably

As for helmets, have a look at the Nitro range, they aren't the top of the pile, but fit well and are comfortable, with a decent safety rating, very well priced too and better than a 2nd hand helmet for sure.

Saitch, I recently fitted a Chinese Mikuni tm 36-68 pumper Carb and 300 kit (292cc) to my KLX chook chaser, and after dialling it in with suitable jets ( also Chinese ) it goes great all the way through the rev range, and is not noticeably different to the genuine article that I fitted to another KLX a couple of years back.

So, should bode well for your purpose hopefully. ymmv

Cheers

[gromit]

Hi Gromit, did the kits come with new needles and seats?, I'd think after sitting for a while there'd still be a fair bit of crap and perhaps even rust in the tank, a couple of cheap filters between tank and carbs can save some headaches


The kits came with needles but not seats, needles were the wrong length.
Gasket, screws, jets, float needle & seat all fitted OK https://www.aliexpress.com/item/1005006447874080.html

There's a filter on the vacuum operated fuel tap in the tank. I haven't disturbed it because I'll probably need gaskets to re-fit.
Plenty of knock-off taps on Ebay and much cheaper than a seal kit !

Starts & runs OK, fuel leak fixed (I can remove the carbs in a few minutes now).

LH thread ball joint turned up, managed to remove the RH thread one from the gearlever (took some filing & cutting). Gearlever now fitted.

It seems whatever you need to do on the bike you need to remove the lower fairing sections !
Radiator may need to be removed to check the front head valve clearances, hopefully the rocker box seals can be re-used as they seem expensive.

Waiting for a replacement screen from China.


Colin

[gromit]

The screen turned up today, all the way from China just wrapped in some thin foam and plastic. I was surprised it arrived in one piece.
Shape is close to the original but 4 holes in it were undersize.
As I was drilling the holes out it crossed my mind that it came from China in one piece and if I wasn't careful I was going to break it !

Removed the rear wheel & cleaned it up and cleaned & lubricated the chain. No sign of hooked sprockets so one less thing to replace.

I had to bend some of the fairing mounting brackets. Someone had tried to steal the bike from the previous owner and dropped it on it's side.
Found the original screws which are hard to replace, a few were missing when I purchased the bike so I'll see if I can find some from Overseas. A lot are oversize button heads and shouldered so difficult to find or expensive if Suzuki still list them.
Screen looks OK now fitted.

Drained the tank and checked the filter, all OK.
Started and it ran OK for a while then slowed & died, wouldn't re-start, fairly sure it's the fuel pump.
Lifted the tank, pulled the fuel line from the pump and poured quite a lot of petrol into the carbs before it backed up, must be the pump !

Reproductions are available on Ebay so I'll order one.


Colin

[gromit]

I can see why the 'naked' version was more popular, taking the lower fairing sections on & off is a pain.

Fuel pump arrived today, typical Ebay purchase......claims to be for the SV650 but not rubber mounted like the original and the hole centres are wrong ! The inlet, outlet & vacuum connection were slightly different but I could work with them.
So....mount the pump rigidly using one bolt or check the original pump again.

I considered using the backplate from the old pump but the gasket was well & truly stuck to the backplate.
I connected a hose to the inlet of the old pump and a short pipe on the vacuum connection to a syringe. Dipped the inlet hose into some petrol & pumped the syringe and got nothing.
Pulled the pump apart, cleaned with carby cleaner again. Sprayed each side of the valves to flush any debris through.
The syringe was still connected so I pulled a vacuum and sucked the diaphragm in (no leaks) then left the vacuum on while I re-assembled the pump so the diaphragm wasn't stretched by the spring behind it.
Dipped the inlet tube into some petrol and pumped the syringe and petrol pumped out of the outlet !!!

Original pump re-fitted, I'll test the bike again tomorrow. I need to warm it up and do an oil change.
Next I'll get the young bloke to get back to the Ebay seller.

While checking the bike today I noticed the fork seals are leaking !
I was going to change the oil anyway but now need to strip the fork legs & replace the seals, probably the originals so over 25 years old.

Colin

[gromit]

I've had it running a couple of times but once it gets hot (which is quite quick) it stops and won't re-start.

First thought is coil packs but it would be odd for both to fail.
At the weekend I'll run until it stops then check for a spark at the front cylinder (relatively easy to get to).

It could still be the fuel supply but not easy to check fuel bowls without removing the carbys again.
I've disconnected the output from the pump and trickled fuel down to the carbys, if it takes a fair amount before it backs up in the pipe then it's back to the fuel pump again !

I did find that when I operated the vacuum operated fuel tap with a syringe, fuel flooded out of the output of the fuel pump. I would have thought that the valves in the pump would stop this happening unless there was a pulsing vacuum supply.
Ebay fuel pump getting returned so I probably need to track down one that is actually a correct fit.

I read that older rectifiers fail but not sure if this fits with the symptoms, I'll check the charge voltage while it's briefly running anyway.

I'm beginning to wonder if this is the bargain I though it was, story of my life........

Colin

[gromit]

Haven't had much luck.
Bypassed the fuel pump which is only needed for the last 25% of the tank as it's lower than the carbies.
Tipped the tank up to get a better 'head' of fuel.

Started and ran for a while then revved up to 3,000 for a few seconds then back to tickover, back to 3,000 then back to tickover.....this kept repeating. Shut it down, covered it up and walked away.
Thought about it for a few days and decided it must be the float level (foolishly I didn't check when the carbs were on the bench).

Started it and this time the revs increased and stayed close to 3,000, pulled the vacuum line to the fuel tap and the revs dropped to tickover. Off with the carbies again !!!

Set the float levels, they were allowing too high a level (Chinese rebuild kit parts !). Pulled the carbies down to ultrasonically clean and the end of one jet sheared off !
Kept my cool and carried on cleaning and re-assembling then refitted them.

This morning I started it and it behaved well, hinged the tank back down and it wasn't happy. With the extra head by tipping the tank it seems to run OK.
I'd charged the battery before starting and as the charger was still there I reconnected it after running for a while and found the voltage had dropped. Next problem could be the regulator which are apparently quite short lived.

I await another Chinese fuel pump, genuine is over $200.

It's on a rear paddock stand, I put a jack under the engine as the next job is replacing the fork seals.
I knew it would need tyres but intended to take it out for a test soon. Cracks in the tread of the rear tyre makes me think tyres are next after the fork seals.

It's not the bargain I thought it was going to be.

Anyone know where I can get a pair of SV650 carbies cheap ?


Colin

[gromit]

The latest Chinese fuel pump from AliExpress turned up today and......it fits ! I probably shouldn't count my chickens until I've actually tested it.
The outlet is a bit close to the frame but just enough room to fit the pipe.

I'll do the fork seals next, just had a cheap seal installation tool turn up. I was going to go the polypipe route but by the time I purchased a piece of pipe and turned something up to fit the seal it would have cost about the same.

Next time I run it I'll check the battery voltage to see if the regulator is OK then start saving for tyres.

Colin

[gromit]

Replaced the fork seals today, I used the screw in the seal method for removal. Saved a lot of time.
The fork seal installation tool worked a treat.

Started and ran OK but then stopped and wouldn't re-start.

Still fuel supply issues I think. more investigation when I get time.....

Colin

[gromit]

Removed the tank and ran a gravity fuel supply direct to the carbys.......works without stopping. Isn't happy initially but once run for a short while it calms down.
The vacuum fuel tap works when I suck on the pipe or use a syringe, maybe it's not operating with the vacuum from the inlet ??

Chinese tap ordered along with some new fuel lines, one split where it's been on & off the tap multiple times. Maybe the vacuum hose was the problem ??

AliExpress is normally quite quick so hopefully I'll get it running reliably soon.


Colin

[gromit]

It started & ran OK then as you drop to tickover fuel floods out of a breather on the front carby !!!
Removed carbies and there was fuel sitting in the inlet tract.

Float height set correctly and float needle shutting fuel off so not sure quite what's going on.

Found a pair of s/h carbies plus a lot of other parts on Ebay so waiting for them to arrive.
Fingers crossed that the carbies just need cleaning, seems the seller purchased a lot of parts to resolve a problem that turned out to be a broken wire. There are s/h coils, a new regulator, switches etc. etc.

Hopefully I can get it running properly then get some tyres.......

Colin

[Saitch]

It started & ran OK then as you drop to tickover fuel floods out of a breather on the front carby !!!
Removed carbies and there was fuel sitting in the inlet tract.

Float height set correctly and float needle shutting fuel off so not sure quite what's going on.

Found a pair of s/h carbies plus a lot of other parts on Ebay so waiting for them to arrive.
Fingers crossed that the carbies just need cleaning, seems the seller purchased a lot of parts to resolve a problem that turned out to be a broken wire. There are s/h coils, a new regulator, switches etc. etc.

Hopefully I can get it running properly then get some tyres.......

Colin

Are the above items genuine?

[gromit]

Are the above items genuine?

The regulator will be aftermarket but the rest of the parts look as though they were from a Wreckers.


Colin

[gromit]

The secondhand carburetors & parts turned up yesterday.

Externally they were in slightly worse condition than the ones fitted but internally much better, all the jets came out and no 'varnish' from stale petrol.
One diaphragm is a bit crumpled for some reason so I'll take one from one of the originals.


I scrubbed them clean with turps then brake cleaner then popped them in the ultrasonic cleaner, it still surprises me how dirty the water gets......


I'm only using the float bowl gaskets, float needles and screws from the Chinese kits, after having a Chinese jet break I'll stay with the Japanese jets after ultrasonically cleaning.

Float heights were way out, the Chinese float needles were slightly longer and fitting those along with some fine tuning got the heights set correctly.

I now need to replace the fuel pipes which means making a couple of 90degree bends (insert a former inside & use a heat gun).

Hopefully.......I'll get it running without issue this time !!

Colin

[gromit]

Fitted the cleaned carbies yesterday and finally.......success ! It starts & runs OK but needs some fine tuning.

On to the next problem.
With a meter on the battery there seems to be no charge when the bike is running. Seems that the standard regulators fail regularly so time to investigate.
Removed the rear bodywork and found that the regulator had been changed in the past. Slightly different model but some very neat wiring to correct plugs to join to the harness.
Amongst the job lot of parts there was a new Chinese regulator so I decided to fit it and see if there was any change.
Still no charging but the regulator became warm as did the wires from the alternator !
Re-fitted the original and basically the same problem.
I'll have to check the wiring from the regulator to earth and regulator to battery, something is NQR.

While checking things over on the bike I found that the sidestand switch has failed. I'm not sure, but I guess it'd be part of the roadworthy test so need to track down one from a wreckers.


Colin

[gromit]

Carried out some wiring checks, all OK.
Started the bike and a healthy voltage across each pair of wires from the alternator.
Re-connected the rectifier, checked output and nothing !

Seems the regulator fitted has failed and the 'new' one in amongst the job lot of parts purchased doesn't work.
Interestingly the new one is from the same supplier who sent the wrong fuel pump (mental note not to use them ever again).

Replacement ordered, hopefully this is the last problem. Otherwise I'm thinking of taking up another hobby, maybe stamp collecting.


Colin

[gromit]

The AliExpress regulator/rectifier turned up.
Once fitted the battery was charging so just need tyres now.

I might get a cheap digital voltmeter so I get a warning when this regulator karks it, they seem to be a frequent failure point unless you spend large amounts on a MOSFET reg from a reputable supplier.

A customer has just offered me an '88 Honda Transalp, looks like one of my boys might buy it. I wouldn't be allowed to buy it unless the Suzuki gets sold first.



Colin

[Saitch]

The AliExpress regulator/rectifier turned up.
Once fitted the battery was charging so just need tyres now.

I might get a cheap digital voltmeter so I get a warning when this regulator karks it, they seem to be a frequent failure point unless you spend large amounts on a MOSFET reg from a reputable supplier.

A customer has just offered me an '88 Honda Transalp, looks like one of my boys might buy it. I wouldn't be allowed to buy it unless the Suzuki gets sold first.



Colin

........and so it goes on! [biggrin][thumbsupbig]

[gromit]

........and so it goes on! [biggrin][thumbsupbig]

Collected the Transalp tonight.
It's been standing for 6 months so needs checking over and a service.
A few bumps, scraps & splits in the plastic panels but the young bloke is happy.
58K on the clock and only $1K.

Hopefully he has less problems than I had with the Suzuki !


Colin

[gromit]

Tyres fitted to the SV650, that's almost doubled the investment in this bike.

Next a roadworthy, mind you the weather is changing so that may go on the backburner. Maybe a permit and a few local rides to a 'place of repair'.


Colin

[gromit]

I've not spent much time on the SV for some months.
Replacement carbies were still causing some issues. They were ultrasonically cleaned, re-assembled with new seals but once the engine was hot, when you closed the throttle it stalled.
Purchased a 90degree screwdriver from Ali Express and fiddled with the idle mixture to no avail (most people take the carbies off to adjust).
https://encrypted-tbn0.gstatic.com/shopping?q=tbn:ANd9GcRbbYcLmH0i2cHqxuX4z3bRUpY6Tcy LRuBrQiRiumIiH0YO15bFRAoxVSB2hWtYFJzZPrpMRC2kvvX-Ii811D8LcYF1NdMdvpPEAKe7ezSs9-WDsdsjbl6L9Js3GbeoN-HZSB01T2w&usqp=CAc

Removed them again, getting quicker at this now, removed jets, checked everything over again. Nothing obvious but a quick test late yesterday and the problem seemed to be resolved........then, when it got hot, the tickover became uneven !

Added to the ongoing carbie problems the Chinese regulator I purchased is putting out over 15V at tickover !
I can't justify the price of a brand name Mofset regulator as this 'bargain bike' is turning out to be anything but a bargain.

The young blokes '88 Transalp is registered & being used. That was a bargain at $1K, all it needed was a silencer, chain & sprockets, a front master cylinder overhaul kit and fresh tyres.

Colin