XS650B : Sidecovers, 2000 SV650 Front End swap

Hi All!

I'm working on my XS650B some. Plan is Kick only, PMA, Pamco. Get rid of the 35 year old electronics, and update the suspension some.

I got the 2000 SV650 front end from Hogrider (Thanks again man!), so here's some pictures of me getting the SV650 front end on along with the rough state the sidecovers are in.

All the pictures are at http://imgur.com/a/m7Q2D Feel free to have a look.

Why the 2000 (First generation) SV650 front end? It uses the same 30mm and 25mm stem bearings (we need to make the stem longer, 0.700" to be exact) so that'll be nice. The axle is 17mm, so the XS650 front wheel bearings work. Both front ends are 755mm long, triples are different installed height but it's seems to work for what I want..I'll just run a taller front tire (I wanted to do that anyway).

Need to make :

• Spacer under the bottom tapered bearing, sets height of the triple away from the neck and recreates the seal surface
• Speedo delete/LH spacer, recenters the wheel in the SV650 front end.
• ~3mm spacers to get the SV650 discs to install to the 90mm Brake Mount Face - Brake Mount Face like the SV650 wheel, Also the discs will be my drill templates for the new Bolt Circle Diameter once the SV650 discs are slugged and redrilled.
• 0.700" long spacer for the neck, to get it to install in the XS650 neck

Had them made at a local machine shop, great bunch of guys. Really happy with the parts.

I'm really happy with the front end. I'll have to build a front fender / brace, but I can do that later. Trying to spread the work around so I don't get burned out on one thing. It will be Black/Aluminum with brass rivets like the side covers.

Next up is de-tabbing the frame, chopping the rear fender and building a seat pan. I'll design a taillight and carve it all out of durham's rock hard water putty, and have it sand cast. I'm using Luxeon Star LXML-PWN2 (http://www.luxeonstar.com/Neutral-White-4100K-20mm-Tri-Star-Rebel-690-lm-p/mr-wn300-20t.htm) triples with elliptical lenses. These things are visible from a crazy distance, and light up the night like nothing else. I really like making sandcast parts. I'm having a bud make me some blown glass lenses (that's the plan so far), it's going to be jewelry for sure.

Enjoy the pictures!

awesome looking build so far.

Really want to see the outcome of the custom rear light. I wish more aftermarket units were brighter as well as being smaller.

The plan is to design a part, make a pattern, development of the product, and reverse engineer it after it meets my needs. The intent is to fit the curvature of the XS650 fender, mount with epdm for a pad/isolator.

It'll be over engineered and cost more than it needs to

Cafe-Dave said:

The plan is to design a part, make a pattern, development of the product, and reverse engineer it after it meets my needs. The intent is to fit the curvature of the XS650 fender, mount with epdm for a pad/isolator.

It'll be over engineered and cost more than it needs to

Click to expand...

so how did you extend the steering stem? cut it, put in 0007 pce welded it? Is the stem aluminum?

Hi Café Dave,

Your bike will certainly stop well.

I am also fitting a 2000 SV 650 front end to my bike. I am building a Tracker and have an 80 XS special frame using KX 450 motard wheels and an Omar’s XR750 type tank.

I have encountered some problems.

The first was the suspension travel. The SV forks have 130mm and using the SV clamps on my set up the font mudguard would hit the lower triple clamp before the suspension bottomed out.

The second was the available steering lock. Using an Omar’s tank on the XS special frame mounts the fork leg hit the tank. Fitting a stop to prevent this would restrict the lock to such an extent that I believed that low speed manoeuvring would prove to be embarrassing. It would probably be fine for riding speeds.

I also felt that the offset of the SV clamps combined with the Special frames 27 degree rake would result in a trail that would make the steering a bit too twitchy for my liking.

I am mentioning this so that other members do not think that the SV front end is an easy swap as in my experience it hasn’t been.

My solution was to make a set of triple clamps with the top clamp of a step down design. The new clamps used a stem pressed out of an XS set up. I have also relocated the tank mounts further back.
With regard to your fork brace there are ones designed specifically for the SV available at pretty reasonable prices.

vincemasi said:

so how did you extend the steering stem? cut it, put in 0007 pce welded it? Is the stem aluminum?

Click to expand...

Hacksaw, measure, file, measure, file, measure. Until I was 0.002" or better to being perpendicular to the stem axis for the top and bottom pieces. Then I designed a insert/spud with the correct OD and a nice fat chamfer to allow for welding.

I had to extend the stem 0.700" more to get the middle ground on thread engagement of the bearing crown nut and triple clamp acorn nut.

Stem is mild steel, magnetic, and I just had the extension made from 1020 steel bar. Hole in the middle so I can run something through there if I want.

Does that help?

Sounds like more work than swapping the stems.
I have a front end off an XS1100 that has a short stem. I plan on swapping it out with an XS650 stem.
Leo

Signal said:

Hi Café Dave,
...

I have encountered some problems.

The first was the suspension travel. The SV forks have 130mm and using the SV clamps on my set up the font mudguard would hit the lower triple clamp before the suspension bottomed out.

The second was the available steering lock. Using an Omar's tank on the XS special frame mounts the fork leg hit the tank. Fitting a stop to prevent this would restrict the lock to such an extent that I believed that low speed manoeuvring would prove to be embarrassing. It would probably be fine for riding speeds.

I also felt that the offset of the SV clamps combined with the Special frames 27 degree rake would result in a trail that would make the steering a bit too twitchy for my liking.

I am mentioning this so that other members do not think that the SV front end is an easy swap as in my experience it hasn't been.

My solution was to make a set of triple clamps with the top clamp of a step down design. The new clamps used a stem pressed out of an XS set up. I have also relocated the tank mounts further back.
With regard to your fork brace there are ones designed specifically for the SV available at pretty reasonable prices.

Click to expand...

Did you swap a 1st Generation SV650 front (Dished brake discs) or a 2nd Generation (Flat brake discs)?

Both the XS650 and 1st Gen SV650 front ends are 755mm extended. I'm going to put 1.1kg/mm to set the sag for my fat ass . I did lower the front end by 30mm and put in a top out spring on top to give me the ride height and travel I want.

Using the 19" XS650 wheel gives plenty of clearance for a fender. I have about 35mm of clearance to the bottom triple clamp. So that's 30mm travel removed (1.181") and extending the neck 0.700", using a 19" tire means I've moved the tire ~1.181"+0.700"+1.000"=2.881" closer to the 1st Gen SV650 triple clamp. I still have about 1.378" of clearance.

I used to do wheel/tire/brake/suspension setups for work, so I really take my time to get this stuff somewhat correct

I have 3.9" of trail using the 105mm offset clamps. Plenty of trail for what I'm doing. Did you use a SV650N or SV650S set of clamps? The N's have a little more offset (I've heard 8mm) to make it easier to retain trail. If the bike is "funny" handling I'll strap on a steering damper from a hayabusa + LSL/Spiegler clamps.

Sorry you've had problems, I'm having a great time. The 41mm forks don't look out of place, and retaining the XS650 wheel really gives the front end a feel of being updated and not tacky.

XSLeo said:

Sounds like more work than swapping the stems.
I have a front end off an XS1100 that has a short stem. I plan on swapping it out with an XS650 stem.
Leo

Click to expand...

It took me 15 minutes to cut the part, 2 hours to draft the components I needed and send it to the machine shop. A week later everything shows up, I take it to a buddy's house and he welded the stem together.

Here's a picture of it w/o the handlebars on. 30mm lower, 12.5" shocks. Static trail is ~3.9" measured.

For the SV types: 99-02 SV650 fronts are all the same, except the '02 got external preload adjusters, which work nice. I have 1.0 KG-MM Race Tech springs and Gold Valve emulators in mine with 10W oil, and it's an incredible improvement. I doubt you will need a fork brace outside of a race track. The 41MM tubes are pretty stout, and should hold up to anything you can put them through with XS parts behind it. FYI, the SV steering angle is 25 degrees, so it's not a far cry away, and is far from a "twitchy" geometry package. Digging the SV front ends. My '02 has 68K miles on it, and still rolling strong. Also, 3.9" of trail should yield excellent stability.

Subscribed, ride reports, we need ride reports!

The bike is currently torn down, I'll probably have it back together and riding mid October. I'll let you know then

what front hub and wheel are you using im thinking of going for a spoked front wheel with late up side down sports bike forks but only want 1 front disc

It is the OEM Yamaha wheel

Subscribed I can't wait to hear how it works out. After pushing mine hard today I need to do a swap.

subscribed

Regarding the front disks, did the 2000 SV650 disks bolt directly to the XS650 spoked hub? I am going to swap an 07 R6 front end onto my 73 XS650. The problem I am having is the R6 disks diameter of the mounting holes is much larger then the XS650 and I am going to have to make an adapter to accomplished this. Thanks!

I had to have the XS650 bolt pattern machined into the Sv650 discs. The Sv650 pattern remains as well, which is a little gangster, but will work just fine.

I welded up a set, but they cupped and ruined the disc mounting faces.

Great thx!