Sotaro SV-R by Moto-R Design

We can now present to you. the Sotaro SV-R by Moto-R Design.

A design exercise to create a track focused motorcycle using the basis of an SV650 engine and GSX-R600 front end. It's lighter and smaller then the bike it's based upon and has it's own, unique style. 

This particular one, "the prototype" uses a completely standard engine from a '99 bike with standard exhaust system and an Arrow end can (off a GSX-R600). The front end is all GSX-R600 and the rear shock is off a ZX-10R. This bike has been designed with LED running lights and projector headlight, along with an LED tail light unit, so could be made road legal fairly easily, though our use will only be on track.

 

If you would like to commission one for your own project, then please get in touch by email. There are already more frames being made on the jig.

SV650 - The Dry Build Commences

Here it is! We have started to do a dry build of all the parts manufactured so far to ensure they all fit when it comes round to put a running engine into the bike. 

The frame was always going to fit, but the front and rear subframes have been designed in CAD, so we need to have them on the bike to ensure everything aligns and the bodywork fits as it should. It also gives us chance to check all the brackets on the frame, fit the battery box, get the radiator mounts in place, locate the fuel tank . . . the list goes on.

 

Below you can see how the front subframe fits with the instrument panel and adjustable headlight unit. Theres still a few more pieces to TIG weld on to fully support the front fairing. The lock-stops have also been integrated into the aluminum piece

 

The comparison below gives you an idea of how the frame has evolved from initial mock-up, through the CAD process and into a prototype frame. Main differences are larger radius' bends in the tubes, removal of a few bosses deemed unnecessary, addition of headstock gussets & side stand bracket sand obviously a higher grade material that has been fully TIG welded.

More photos as and when progress happens!

SV650 - Frame Closeups

The frame is also now complete in Solidworks so we have grabbed a few closeup shots of some of the details. 

Chamfered edges feature on all the bosses to minimise any excess weight.

Headstock gussets and aluminum bearing inserts. This allows for easy interchanges between different fork setups which use different sized bearings with the insert clamped into place using pinch bolts.

SV650 - Matt Black Show Bike

 

Well, we've hit the deadline with a few hours to spare, so these shots were taken outside the workshop shortly before being loaded up and taken to the BMF Show.

 

There's been far more then just a splash of colour added so I'll go through the list of upgrades that have gone on. The front end is all GSXR 600, forks, brakes, wheels and handlebar controls. Straight forward swap-over from the standard SV front end. At the rear is an '09 ZX10 shock, again, a hassle free change from the standard shock as the dimensions are very similar. The rear pipe is an Akrapvic carbon unit, with a specially made exhaust hanger coming off the subframe unit.

In addition to all these performance upgrades, new light units are present. There's a bi-xenon projector lamp which will be housed in an aluminum shroud coming off the front subframe, with daylight running lights either side and the rear will be an LED arrangement, though these are still work in progress.

 

  

Its far from finished, but this stage gives a great idea of how the final bike will look. Now, lets get one up and running!

SV650 - Time For An Update

 

The fibreglass bodywork has begun to make its way onto the bike. Alignment is going to take some time as there are no mounts on the frame so these will need to be made as we go along.

 

 

Clay Photo Session

Its the end of January and the SV concept has been wheeled out from the workshop for the first time. Its taken a little longer then planned to finish the clay and get it symmetrical but its now there and awaiting the first of the fibreglass molds to be taken.
 

There's a few more photos below of the clay model alongside the original SV.  Its certainly taken on a different appearance from standard.

SV650 - Dark, Cold Winter Days

 The heaters are back in action and the flask is full of hot coffee. Time to get the clay model finished.

Check back by the time the years out, I expect the clay will be completed by then.

SV650 - November's Progression

The clay is nearing completion in terms of design detail with surfaces beginning to be come finalised. Once this stage is achieved, the bike can be taken outside to finally assess the design from a distance.

SV650 - Hows it looking?

The design as it stands at the beginning of October.

SV650 - Progression in Clay

 

 

The SV project keeps progressing! Now its in clay, the design is being constantly refined to work with the SV package and achieve the original design goals.

SV650 - Clays Arrived

The arrival of some Chavant styling clay to finish the design on the SV.

SV650 - Beginning To Take Shape

Over the past few weeks, a wooden armature has been built around the mock-up frame and engine. Now its just a case of cladding the wood with Styrofoam in order to apply the clay and really start the styling.

Its a bit of a labour intensive process and as usual has taken longer then expected. Taking a little bit of extra time at this stage will mean the clay modeling phase will be sped up. Its beginning to take shape now!

SV650 Concept Rendering

 

A concept rendering for the SV650 project. The styling of the bike is take a very clean, simple form with a "less is more" aesthetic, detailed with etched aluminum features. The front end of the motorcycle will be dominated by a single bi-xenon projector headlight unit, complimented with daylight running lights to form an aggressive look in the opening of the air inlets.

SV650 Chassis Design Concept

This is the initial design for the chassis, consisting of the frame, subframe and swingarm. With only reference images to ork off for dimesion, its expected to change a vast amount, but its heading in the right direction. 

The frame has been designed to be built as a steel trellis structure. The main reason behind this is the simplicity to manufacture in low volume numbers, but they also have a very elegant aesthetic.

You may well recognise the reference image in the background being that of the RSV4 Aprilia. Thats no bad thing, as that's a very compact, sweetly packaged bike!

Showcase Project

To this date, Moto R Design have been doing small freelance projects for a number of clients, but the desire to be involved with a more complete motorcycle project has been ever present. This has lead to many hours of thought on various design projects, from single cylinder racing machines to three-wheeled trikes, along with everything else in between. 

With the weaker design project ideas put to one side a clear candidate had emerged, which was the humble Suzuki SV650. Im a big fan of small, narrow engines and the SV650 lends itself perfectly to the type of bike we'd like to design, along with being very popular with many other bikers.

So the general idea is take a SV650 as a donor bike, use that great little engine and some of its components, and re-style it into a much more compact, desirable sports bike. Along the way, any improvements to the performance or handling that can be made will be worked on, to make the bike as complete and enjoyable to ride as possible. The SV has a great following, with race series such as the "MiniTwins" here in the UK, and is an easy base for upgrades of components from the GSXR series of bikes.

The main goals for this project are to demonstrate the capabilities of Moto R Design. The opportunities have arisen to move into an existing workshop in the not too distant future, and create a studio / workshop facility that is setup specifically for motorcycle design work. So when this is in place, its time to really go for it, and start designing some really stylish motorcycles.

Now the design process begins. Over the next few weeks many ideas will get sketched out and thought about and the project will begin to take-off. Now we just need to find a donor bike . . .

M28 Exhibits at Coventry Transport Museum

As part of the Degree Show, selected works were displayed at the Coventry Transport Museum. There was a little more room to display the bike, so we put it next to one of my fathers bikes. 

The Norton M28 Concept bike alongside an original 1937 International . . .

Tape Drawing

A tape drawing. This one is of a design I was working on whilst on placement at Ducati, and having never done one before, it was an invaluable experience to have Bart and the Ducati design team guide me through the process.