SV650 Project Bike – Making a Short Throw Throttle and New Brake & Clutch Levers

SV650 Short Throw Throttle ModificationThe next phase of the SV650 project bike is fine tuning the controls of the bike.  I am really not happy with the amount of effort that is needed to twist the grip all the way to full throttle.  As the SV650 is considered a beginners bike Suzuki made the throttle 1/4 turns to full open.  Well my riding style doesn’t allow me to easily go from full closed to full open without adjusting wrist or hand positions on the fly which is not exactly good while on the track.

SV650 Short Throw Throttle Modification

After searching all over for a possible solution I found one on the Canyon Chasers website.  To modify the SV650 throttle all you need is to buy a Yamaha R6 Throttle Tube Part Number 5SL-26240-01-00 which goes for about $8 on eBay.

Now you take the Stock OEM SV throttle tube on the Gen-II and match the notches. The pink marks in this image represent the material that needs to be cut away.  Install and now you have a short throw throttle that doesn’t break the bank.

New Parts Unbreakable ASV Levers for the SV650

Suzuki SV650 ASV Unbreakable LeversAs the previous topple of the bike off the sidestand showed how quickly you can shatter a lever.  After investigating the lever further I noticed some hairline cracks in the clutch handle.  Well I cannot have that.  So I again went back to the SportsBikeShop.co.uk and ordered some black ASV Unbreakable clutch and brake levers for the SV650 Project bike.  I hope this time around I will not have to test out this particular part.

The reason I choose the ASV levers  is because they feature a special pivot design that allows the lever to fold out of the way in the event of a crash or topple. They simply pivot outwards and spring back(reducing the possibility of breaking a handle). The pivot junction is precision sealed with zero play or slop. Also, by simply adjusting a setscrew on the lever the reach can be adjusted to accommodate different sized hands and tune for the ideal brake and clutch response.

Pictures will follow after installation of the new clutch and brake levers.

Following the new parts set to go on it looks like the final track day of the year before the weather will change will be September 21.  So I am hoping also to have the chain and sprockets sorted out by this time.  I am still waiting on a chain tool in order to press fit my new X-Ring chain on the yet to be installed Renthal Sprockets as I want to install everything new at the same time.