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My take on a SV 650 Cafe Racer

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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 12:07 - 05 May 2022    Post subject: My take on a SV 650 Cafe Racer Reply with quote

This is my first post on BCF so thanks
I am a older rider but have only commuted on my bikes so no race skills, but I wanted to make a cafe racer that would go as well as it looks.

I am retired now and have a couple of cars to restore but felt building a bike would give me some quicker gratification to get the ball rolling.

I do it all myself except welding bracket on the .9mm light weigh exhaust.

Feel free to comment good or bad. I will try to explain each stage
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gt alex
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Joined: 01 May 2022
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PostPosted: 12:11 - 05 May 2022    Post subject: Reply with quote

made some stands
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gt alex
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Joined: 01 May 2022
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PostPosted: 12:46 - 05 May 2022    Post subject: Reply with quote

I am learning to post pictures sorry having trouble, looks like some just don't want to up load
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c_dug
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Joined: 04 Sep 2007
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PostPosted: 20:07 - 05 May 2022    Post subject: Reply with quote

The bike looks cool.

You may have more luck uploading your pictures to https://imgur.com/ and linking them from there. The BCF uploader can be a bit pernickety with larger files.
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MarJay
But it's British!



Joined: 15 Sep 2003
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PostPosted: 20:27 - 05 May 2022    Post subject: Reply with quote

I like SV's, my second 'big' bike was a 2001 SV650S.

Your rear 'fender' looks very close to the rear tyre in that picture.

A lot of members of this forum seem to have a weird aversion to SV's. I've never really worked out why.
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 06:48 - 06 May 2022    Post subject: Reply with quote

more pics wiring/rear tray
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 08:36 - 06 May 2022    Post subject: Reply with quote

In the belief less is more.
lighten the flywheel, lithium battery, lighter dash cluster, 1 carb and no air box, drill holes
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struan80
World Chat Champion



Joined: 04 Nov 2014
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PostPosted: 09:52 - 06 May 2022    Post subject: Reply with quote

Wow. Good stuff mate. Smile
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 10:24 - 06 May 2022    Post subject: Reply with quote

Some of the mods done and currently making a fuel tank to complete the cafe racer theme. For me performance is as important as style.

TRE mod
Custom Rear frame retained hinged Tank
Hump Seat
Gen3 black widow decat system
Reverse cone muffler with custom baffles
Custom single carb conversion
Rear sets with self returning folding pegs
Harley rubber gaiters on forks
Clip ons with cut drag bars inserted of more adjustment
Radial brake 17.5 M/C with matching clutch lever
Bar end mirrors
rear spring/shock adjustable compression and rebound 8mm shorter than stock
custom bog bones to restore geometry
upgraded .9 front spring, cartridge emulators 15w oil
Electrics modified for clean under seat look. lithium battery, aftermarket dash, led tail light, indicators.
5 3/4 inch headlight 55/55w H4
shortened front guard
headlight cowl made from piece removed from front guard
(currently changing to a 1/2 fairing
dual front brake lines
Lightened flywheel
4 deg ignition advance using offset flywheel key
520 chain set with alloy rear sprocket and 14t front
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 06:51 - 07 May 2022    Post subject: Reply with quote

I fitted a Black Widow decat gen Gen3 exhaust
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 06:12 - 08 May 2022    Post subject: Reply with quote

Making a new tank, using the top half of a Honda tank, a wire hoop from the seat and around the frame.
And some duct tape modelling.


Last edited by gt alex on 08:51 - 08 May 2022; edited 1 time in total
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gt alex
Two Stroke Sniffer



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PostPosted: 06:36 - 08 May 2022    Post subject: Reply with quote

current tank progress
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gt alex
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Joined: 01 May 2022
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PostPosted: 06:49 - 08 May 2022    Post subject: Reply with quote

The carby with a car air filter which is temporary. Since dyno testing the manifold has been blended into the ports and to the carb.
Also since testing the TPS has been adapted to this carb.
The front 1/3 of the new fuel tank will be the air box, how it will fit together has not yet been worked out.
I may try spacers under the carb to see if some more power can be had.
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 12:30 - 22 Aug 2022    Post subject: Reply with quote

A little more progress. Handle bars in position to suit the fairing. Running my custom bent bars allowed me to rotate them to maintain ergonomics.
Smoothed some welds and massaging knee and bar dents, slapped some black primer on to just get better prospective.
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Omegasteve
Two Stroke Sniffer



Joined: 24 Aug 2022
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PostPosted: 13:39 - 26 Aug 2022    Post subject: Reply with quote

Making quick progress! Looks great so far
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gt alex
Two Stroke Sniffer



Joined: 01 May 2022
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PostPosted: 10:59 - 27 Aug 2022    Post subject: Reply with quote

Omegasteve wrote:
Making quick progress! Looks great so far

Never quick enough. Working on the hinge at the back of the tank, once done I will fit the filler bung and fittings for the petcock and sender.
Finish panel beating because last change with access before sealing up the rear part of the tank shaped for the seat.
Then I will leak test ad weld up leaks, then braze over all welds to destress welds and add material.

Then sort out the air box end (I don't even know how I'm doing that yet)

Then just because I want to be sure of no leak I will use a tank sealer.
then strip it back bog and paint fit the cap petcock and sender and it's done.

Then I have to finish fitting the fairing.
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gt alex
Two Stroke Sniffer



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PostPosted: 11:32 - 29 Aug 2022    Post subject: Reply with quote

Been making the tank hinge and am happy with the alignment so tomorrow hope to do the gusseting to give it strength and rigidity.
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gt alex
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PostPosted: 12:32 - 10 Sep 2022    Post subject: Reply with quote

Flattening the top of the tank ready to fit the bung for the new old school cap.
I have still not welded in the back of the tank so there is access for panel beating and I can tip it on its end and fill it to find its true capacity.
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gt alex
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PostPosted: 12:41 - 10 Sep 2022    Post subject: Reply with quote

After the fuel tank end is finished I need do the air box end.
This is the plan, hope it doesn't hurt the engine power.
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gt alex
Two Stroke Sniffer



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PostPosted: 02:39 - 11 Sep 2022    Post subject: Reply with quote

Just measured the new tank capacity. My latest guess had been 12ltr but I was a cup shy, 11.75 ltr and that's that.

That'll do donkey.
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gt alex
Two Stroke Sniffer



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PostPosted: 06:06 - 05 Oct 2022    Post subject: Reply with quote

After creating a lot of distortion while silver soldering the cap bung and the making it worse trying to beat it out while I was sick with covid.
I then bought a pin welder to help me restore the shape.

I have resorted the shape to within 2mm. I know it still looks very rough but when I run straight edges on it I am not game to go closer or even smooth it for fear of creating highs that will become a problem when finishing it off.

The plan is once the petcock and fuel level sender fittings are are done, I will do a final leak test.

Then

1. strip it and epoxy prime it.

2. cover the whole thing with fiber glass re-enforced filler.

3. then finishing filler and 2k primer sand 400 finish and paint..

4. add a tank sealer.
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