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Old 11-09-2012, 12:38 AM   #1 (permalink)
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Default SV650 Clip-On Installation

Hey everyone, since I had a set of SV650 Clip-Ons on hand (thanks to FaceOff for the idea Installed SV650s clip-ons) , the time, and finally the knowledge and tools, I decided to lower the front end and install them, while I source more parts for my future 636 front-end conversion.


Before I continue, I would like to say I am definitely not a mechanic or expert, and I won’t be going into too much detail since I’m probably going to be giving more detail than most people do in general.


So, feel free to reference this thread at your own risk.


Step 1: I lifted the rear of the bike.
Step 2: I removed the fairings with help of TonyBKK’s fairing removal instructions.
Kawasaki Ninja 650R ER6f Motorcycle Fairing Removal Instructions 2009-2011





Step 3:I started taking some measurements before I lowered the front end. The measurements were for the location of where to drill the hole into the left SV650 clip-on. It was not the ideal way to do it but I was missing something to prop up the jacks for the front-end. Here is a series of pictures to give you all an idea of where the hole was drilled.











Step 4: Later that morning I went Lowe’s for some would to prop my car jacks up. I had them cut up what I think was a 2X12X12 into 10 sections of equal length with some extra wood left over. These are 3 ton jacks by the way. I had a friend position the jacks while I lifted the bike from the front wheel. The jacks should be pretty close to where they will lift the bike before someone lifts the wheel. That way it should take at most 10 seconds. The bike is not light as you can imagine so some mechanic gloves would help.



Step 5: I marked the original positions of where the clamps held the forks.





Step 6: I started to loosen the bolts on the clamps using some of these.


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Old 11-09-2012, 12:43 AM   #2 (permalink)
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Step 7: I had my friend use a flat head screwdriver to open the clamps a little as I moved the forks upward. The extra piece of wood came in handy to prop the wheel and forks up.



Step 8: I put the clip-ons on and measured the distance from the top of each clip-on to the farthest edge of the cylindrical part of each fork.




Step 9: I put the controls on next, along with my old grips, and new bar ends (SV650 bar ends).




Step 10: I put on the fairings and took care of the clearance issues. The picture was taken before I had the front master cylinder and clutch where I wanted them, but pretty much I would say the front master cylinder should be as close as it can get towards the ignition and the clutch as far left as you can get it.






Here are some other pictures that can be used for comparison.






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Old 11-09-2012, 12:49 AM   #3 (permalink)
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Also I used a click-type torque wrench to tighten the bolts back from harbor freight tools. I had gotten the torque specifications a long time ago, and can't recall from where exactly, but it was through this forum. The torque to re-tighten the bolts was 15ft-lbs
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Old 04-14-2013, 11:12 AM   #4 (permalink)
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Nice Write-Up! How's the ride with them?
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Old 06-19-2013, 01:42 PM   #5 (permalink)
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Thanks! Sorry for this really late reply, but the ride with them was great!
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Old 06-19-2013, 02:12 PM   #6 (permalink)
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wow, looks good, nice work!
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Old 06-20-2013, 03:39 PM   #7 (permalink)
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Having ridden probably 10k miles with clipons I went back to handlebars. While I preferred the more aggressive riding position, lowering the front that much makes it handle like crap. Going back to handlebars I feel like I can just glide through corners rather than having to push it through with the clipons.
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Old 06-20-2013, 07:03 PM   #8 (permalink)
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Quote:
Originally Posted by Bboytaktix View Post
wow, looks good, nice work!
Thanks!

Quote:
Originally Posted by bob_hackr View Post
Having ridden probably 10k miles with clipons I went back to handlebars. While I preferred the more aggressive riding position, lowering the front that much makes it handle like crap. Going back to handlebars I feel like I can just glide through corners rather than having to push it through with the clipons.

Haha to each his own then, but there are two other guys on this forum who have liked and have used these clip-ons as well.
Plus, you're not the first to bring up a dislike for the new handling after lowering the front end, which is why some people suggest lowering the rear end at the same time as the front end.
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Old 06-21-2013, 03:49 PM   #9 (permalink)
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I have an adjustable aftermarket shock that is -40 mm and it didn't seem to help. With -10 mm (I think) at the front and -40 at the back it's perfect for me now.
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Old 06-21-2013, 09:22 PM   #10 (permalink)
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Nice! I'm glad you found that sweet spot
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