Introduction: SV 650 S Handlebar Conversion

Two types of handlebar exist in the motorcycle life. The sport shaping and the touring. If you look for pics about the Sv650 S you will see that it has got the first mentioned. It is good-good but for longer journey not so comfortable. If my wrist, waist could speak...

Since I am planning a longer trip to south europe (1000km far from home) it was the time to get a new handlebar system on my SV650S. I tought 1 month is enough to design a unique one :)

It is important to mention that I did not want to modify the original parts, everything will be put aside into a box. I want to preserve the items on their original shapes.

In this instructable I would like to show how I made this conversion on my Sv650S.

Step 1: Measure

Take a tape measure, ruler and a caliper. Measure twice or three times!!! Start with the top clamp of the forks. The positions of the holes, diameters etc. Draw it down onto a paper or use a CAD software (I used CATIA). Secondly, measure the existing handlerbar diameters, lengths etc. Sketch them down as well. If almost the dimensions are known, start think about the required lifting height of the handlebars.

At the beginning I planned that 150mm lifting would be perfect. It is a bit more then the SV650 N touring handlebar. So, it should be more then enough.

Step 2: Design

I try to design such a conversion kit which is enough rigid, strong. Almost all the parts were made of Al. After some sketch I build the model of the handlebars in Catia. Not to forget during the modelling, measure and measure again!!

The basic concept was to create such parts which are good for the left side and the right side as well. In this case all I had to do is double the part quantity. Threre was no need to write G-codes and use CAM twice and setup the machine twice( the time is money :) ). All the parts are mirrored.

When the 3d was finished I started to make drawings. Some parts will be manufactured on CNC milling machine and some on lathes.

Step 3: Manufacturing

Using the drawings and the models I started to manufacture. The most complicated parts( clamps on the forks) were made on CNC machine others on lathes and traditional milling machine.

The CAM software I used for coding is the AutoDesk Fusion 360. Since I use it I really did not find any unsolvable problems. Really good, user friendly CAM software.

Step 4: Let's Start

When all the parts are ready to install, I had to investigate how to take apart my SV guardedly, not to damage other parts. The tank is opaneble. The air filter house is easy to unconnect. The biggest problem was the upper triple tree clamp. Unfortunately , with time (17years old bike) the joints could be very tight. Using hammer , wood, Al rings etc. not to damage Al parts, the operation of the upper clamp took 3-4 hours (due to bad sequence). If you want to take apart as well, here are the steps which went to success for me:

1. Loosen the main nut on the middle of the upper clamp.

2. Loosen the two M8(?? ) screws which are thighten the clamp to the forks.

3. Loosen a bit the lower triple tree clamp (Be carefuly beacuse the forks easily slip out their clamps, and hard to position back again) This step is necesarry because between the two clamps the forks are streched.

4. Carefully, try to knock the upper clamp form the bottom(somehow :) , I know there is not too much space available)

5. When you see that the clamp is started to move , thighten the lower clamp screws just ensure against the above mentioned slipping out

6. With further knocking of the upper clamp we can unattach it totally

After taking apart the original handlebars I put on the new parts. Due to increased height it is necessary to find another position, routes for the cables,lines.

Two main cables need to be replaced with longer one. The clutch cable and the upper brake cable. I've bought a new SV650 N (higher handlebar) clutch cable for approx. 20 dollars and new brakelines. Due to the ages of the rubber brakelines I decide to replace all of them to SS brakelines for SV650 N(longer) as well. With this two longer parts and new routes , at the lifted position nothing strained, the steering could move easily.

Step 5: Results

Finally, when all the new parts were in position one thing remained. I left the lenght of the turned parts. After all setting, adjustment I unattached the bars again and made the final lenghts of them.

Results? Everything moves easilly. The total lifting comparing to the sport handlebars is about 120-130mm. Totally different feeling. :)

Since the conversation I have ridden about 200-250km and feel no pain at all.

Notice that with this solution the possibility of the raising-sinking of the bars are remained.

It was just an SV , the principle is the same in case of YOUR bike as well!!

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