Thread: Suzuki SV650S ?

Originally Posted by 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

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

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

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

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

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

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

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

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