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Thread: 99 Millie to 02 conversion with Pics

  1. #1
    Baby Twin darrenb1's Avatar
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    99 Millie to 02 conversion with Pics

    Hello RSV owners, i thought i would start a post to show changes from a 1999 RSV conversion to the next style change.

    The conversion started pretty much from the day i bought the bike.

    After filling the tank to the top, i noticed a very strong petrol smell all the time and had a look around, close inspection i found fuel leaking on to the airfilter and realized i had a small leak from the bracket part of my tank.

    with fear of riding the bike (had it just a day) i ordered the cheapest tank i could find on the bay.. this was a 2002 resin tank.

    I purchased the tank, Hoping i could fit the mesh sides from the later models..

    Here is the original purchased RSV (99)

    Attachment 4283IMG_1291.JPG

    The new 2002 resin tank arrived, i had to remove the petrol pump from the original tank, this is where i found some changes..

    (1) the breather & overflow pipes were built into the resin tank, the original had the pipes going through the pump manifold - i had to blank these off.
    (2) the pump manifold used longer bolts than the resin tank.
    I found out the hard way by over tightening and popping one of the inner bolt holes (built into the resin tank) - i had some work there, removing the hidden
    nut encased inside the resin tank, I was able to resin one back in place.
    (3) I tried three times to get a good seal on the pump manifold, but it leaked every time. With the help of this forum i used the special Loctite fuel sealer.
    (4) Fuel filler - completely new design, required the plastic filler section to be inserted before the resin tank could accept the original filler lock & cap.
    (5) RSV zone info suggested i needed a newer sub-frame as holes did not match exactly - i could have made some but wanted to do the best job possible.
    I found one of those too.

    Here is the original steal Tank

    IMG_1396.JPGIMG_1386.JPG

    New resin Tank finally fitted!

    IMG_1357.JPG

    I then wanted the mesh sides, as the new tank is deeper and cant have the plastic sides of the 99 model.. I soon found some and installed, picture above shows them fitted. Griff kindly had to tap some holes in the frame for me... Thanks again Griff..

    As you can see the bike is getting a little multi coloured now, so i had to find a matching seat unit..

    see the original seat unit above pics...


    The new seat unit came, installed...

    IMG_1703.JPG

    EDIT STILL TRYING TO ADD MORE PICS - IS THERE A LIMIT (they are all small)

  2. #2
    Baby Twin
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    The pics are tiny lol ! Wat happend

  3. #3
    One Liter Duc Eater cheesy's Avatar
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    I turmed my tri colour 99 to a tri colour 02

    looked mint

  4. #4
    AMA Pit Boss redratbike's Avatar
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    just click on the pics they come up bigger

    Cheesy your bike looked great ..hows the tuono makeover going?

  5. #5
    Baby Twin darrenb1's Avatar
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    Tiny Pics

    Quote Originally Posted by nazzurro19 View Post
    The pics are tiny lol ! Wat happend
    Not sure.. they uploaded as big pics and expand when selected.. could be a forum setting..

    here are some more pics.. Just finished installing a new Meta Alarm, cant fault it for build quality install took around 3.5 hours inc the engine immobilization, still have the seat sensor to install, and i'm going to add a couple Meta Microwave sensors.. set to about a 8" away from the bike: if someone gets too close it will go off.. lol

    just before changing the sub-frame
    IMG_1327.JPG

    Meta Alarm Pro Fit
    Untitled.png

    New side panels, had to remove the longer 99 fans, will be needing some 02 onwards..
    IMG_1722.JPG

    New Belly Pan
    IMG_1723.JPG

    Getting there now..

    IMG_1699.JPG

    All original removed bits are available, see the fist pics for condition.. (very good)
    Last edited by darrenb1; February 24th, 2013 at 11:00 AM.

  6. #6
    Baby Twin darrenb1's Avatar
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    Any answers to the small pics? i'm just using the insert picture button above this text.. the pics have been re-sized for the net but i tried an untouched 2Mb pic too..

    for now just click on the pic to make it original size.

  7. #7
    Baby Twin xpanco's Avatar
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    Looking good,I got a 99 too...same colours as yours,will keep it original(for now)

  8. #8
    Baby Twin darrenb1's Avatar
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    Thanks Xpanco, if you need any panels, let me know.

    A quick question if you don't mind, knowing you have the same bike.. if pulling away in a too high gear, do these V-twins make a lot of noise (very lumpy) sounds like its damaging the engine almost?

  9. #9
    Baby Twin darrenb1's Avatar
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    This thread needs moving now there is a new board for RSVR plus the original Mille..

    Is there a way i can edit the thread name to correct the word "Mille" in the title?

  10. #10
    Baby Twin xpanco's Avatar
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    It does sounds like there's something loose in the engine...aparently the 99 meant to be aggressive anyway...

  11. #11
    One Liter Duc Eater w00dzy's Avatar
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    Looking good man

  12. #12
    Baby Twin darrenb1's Avatar
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    Thanks w00dzy, a long way off yours though.. love your thread..

  13. #13
    One Liter Duc Eater cheesy's Avatar
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    Looking good matey

    Here was my version i did darren



    Mark, its getting there, few more bits & bobs to go

  14. #14
    Baby Twin darrenb1's Avatar
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    wow looking good.. did you have the frame coated (black) ?

    I like the way you have kept the original colours.
    Did you change the wheels, brakes and shocks too ?

  15. #15
    Baby Twin darrenb1's Avatar
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    going to try another image upload.. see if its big this time..

    IMG_1697.JPG

    small again, image is over 700 pixels, should be full screen..

    I'm adding by clicking the "insert image" icon, then choosing the pic, then hitting "upload"

    Anyone know what I'm doing wrong?

    Darrenb
    Last edited by darrenb1; March 1st, 2013 at 11:13 AM.

  16. #16
    Baby Twin darrenb1's Avatar
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    Cheesy, did you need to change your cooling fans for the carbon insert to fit?

    like the exhaust hanger too, have you still got that beauty?
    Last edited by darrenb1; March 1st, 2013 at 11:17 AM.

  17. #17
    One Liter Duc Eater cheesy's Avatar
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    Hi matey

    Yep i stripped it down & had frame, swinger,clock braket, subframe, caliper carrier powder coated

    Forks & Brake & wheels from an 02 Rsvr

    Ohlins rear shock from an o7 rsvr

    Smaller fans from an 02, (black Plastic)

  18. #18
    Baby Twin darrenb1's Avatar
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    It does look the business Cheesy..

    I have a carbon Front / Nose section on its way.. been watching it since before xmas on the bay.. should help blend my colours a little better..
    will pop some pics up when it arrives.

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