BergDonk's DR650 - Page 2

a1fa · 12-21-2010, 12:01 AM

Very nice bike!

BergDonk · 12-21-2010, 12:02 AM

BergDonk · 12-21-2010, 12:28 AM

Quote:

Originally Posted by a1fa

Very nice bike!

Thanks, they are a fun thing, but its got 2 wheels and an engine, so by definition....

LukasM · 12-21-2010, 12:50 AM

Nice bike Steve! Looking forward to seeing the rest of the build.

BergDonk · 12-21-2010, 12:55 AM

What I tried to do with the fork adaption was not to cannabalise anything so that where I used the stock parts, they are untouched. I also wanted to minimise the expense, so kept the stock instruments etc. The only thing that was too hard was getting the steering lock to line up. I could get it to work but would never be able to remove the key because of the bar mounts being further forward on the KTM triple clamps.

I trusted LukasM http://www.advrider.com/forums/showthread.php?t=239519 on his advice re the steering head bearings, and it works so far, ie keep the Suzuki cups in the steering head and the KTM races will line up. the bearings are sized differently, ie 29 x 50.25 x 15 KTM vs 30 x 52 x 16 Suzi but it seems to work OK. The rollers are in full contact with the cup. A couple of shim washers to lift the top clamp to clear the damper post mount and we shall monitor durability. May end up fitting a sleeve to the KTM shaft and just use the Suzi bearings, dunno.

$AU costs for the front end conversion:
$520 KTM 08 SXF forks and triple clamp, with bearings - ebay
$30 Husky guard - local wrecker
$105 DRZ400 SM headlight mounts - local wrecker
$32 KTM white fork shrouds - ebay
$8 Suzuki stickers - ebay
$142 MSC KTM submount for damper - MSC

I also got 2 sets of head bearings, just in case, but as yet unused from ebay for about $100

I also had some scrap steel and bar stock for making adaptors etc and an axle and lock nut in the shed, and miscellaneous bolts, so no direct cost as such.

Steve

BergDonk · 12-21-2010, 01:14 AM

Still to come is the Ohlins, a new bash plate from KTMatt and some pannier frames.

I've also fitted a Brembo master cylinder to the front brake for improved control, a definite improvement. TM do it, so it must be good, although the other way around!

And I ordered a 39 mm FCR today too I can't help myself

but my perfectly set up Bergs create a benchmark

Steve

BergDonk · 12-21-2010, 01:16 AM

Quote:

Originally Posted by LukasM

Nice bike Steve! Looking forward to seeing the rest of the build.

Hey, thanks. You, Mezo, and Snowy got me thinking

At least I have someone to blame when the wife looks at the bills

Steve

BergDonk · 12-22-2010, 02:38 PM

Top chain roller torn out. I repaired it, relocating it abit, and adding a strap to the frame crossmember from under the bolt head. So far, so good.

If you look closely, you can see a crack in the top middle of the chain guard. Its stuffed too. I replaced it with a Kawasaki GPX250 one, a bit taller.

BergDonk · 12-22-2010, 02:41 PM

The stock chain guide is fragile. A replacement from Procycle and I added a brace on the inside too. Bolted to the inside of the swingarm with nutserts.

BergDonk · 12-22-2010, 02:43 PM

The FMF header makes a difference.

Fastway pegs I like, and the mount is cut down and rearset.

BergDonk · 12-22-2010, 02:44 PM

The seat is stock with a Yamaha XT600 foam added in, and the sheepskin too. Better for my bum and dodgy old knees.

BergDonk · 12-22-2010, 02:45 PM

The Megacycle muffler
The racks are work in progress.

BergDonk · 12-22-2010, 02:48 PM

The main rack is an old Ventura that I've adapted.
The toolbag is a Kelly
The lower rack is from the wife's KLX250 and replaces the stock tailight. The replacement tailight and guard extension is Berg one I had lying about.

BergDonk · 12-22-2010, 02:50 PM

OK, so I seem to have the picture thing working now. Enjoy.
More to come, I might have the shock tomorrow.

Steve

tdrrally · 12-22-2010, 02:56 PM

very nice

it looks like you sail around the horn with that front end

12-21-2010, 12:02 AM	#17
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	__________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build BergDonk screwed with this post 12-22-2010 at 02:04 PM

12-21-2010, 12:50 AM	#19
LukasM Beastly Adventurer Joined: Nov 2006 Location: Vienna, Austria Oddometer: 4,900	Nice bike Steve! Looking forward to seeing the rest of the build. __________________ Proud member of the HUSABERG ADVENTURE TEAM! '12 Husaberg FE570, 09 KTM XC-F/ 450 RFS hybrid, 07 KTM 450 SMR, 08+09 BMW F650GS twins/F800GS conversion, 03+05 YZF-R6

12-21-2010, 12:55 AM	#20
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	What I tried to do with the fork adaption was not to cannabalise anything so that where I used the stock parts, they are untouched. I also wanted to minimise the expense, so kept the stock instruments etc. The only thing that was too hard was getting the steering lock to line up. I could get it to work but would never be able to remove the key because of the bar mounts being further forward on the KTM triple clamps. I trusted LukasM http://www.advrider.com/forums/showthread.php?t=239519 on his advice re the steering head bearings, and it works so far, ie keep the Suzuki cups in the steering head and the KTM races will line up. the bearings are sized differently, ie 29 x 50.25 x 15 KTM vs 30 x 52 x 16 Suzi but it seems to work OK. The rollers are in full contact with the cup. A couple of shim washers to lift the top clamp to clear the damper post mount and we shall monitor durability. May end up fitting a sleeve to the KTM shaft and just use the Suzi bearings, dunno. $AU costs for the front end conversion: $520 KTM 08 SXF forks and triple clamp, with bearings - ebay $30 Husky guard - local wrecker $105 DRZ400 SM headlight mounts - local wrecker $32 KTM white fork shrouds - ebay $8 Suzuki stickers - ebay $142 MSC KTM submount for damper - MSC I also got 2 sets of head bearings, just in case, but as yet unused from ebay for about $100 I also had some scrap steel and bar stock for making adaptors etc and an axle and lock nut in the shed, and miscellaneous bolts, so no direct cost as such. Steve __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-21-2010, 01:14 AM	#21
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	Still to come is the Ohlins, a new bash plate from KTMatt and some pannier frames. I've also fitted a Brembo master cylinder to the front brake for improved control, a definite improvement. TM do it, so it must be good, although the other way around! And I ordered a 39 mm FCR today too I can't help myself but my perfectly set up Bergs create a benchmark Steve __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-22-2010, 02:38 PM	#23
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	Top chain roller torn out. I repaired it, relocating it abit, and adding a strap to the frame crossmember from under the bolt head. So far, so good. If you look closely, you can see a crack in the top middle of the chain guard. Its stuffed too. I replaced it with a Kawasaki GPX250 one, a bit taller. __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-21-2010, 12:01 AM	#16
a1fa Riding Nomad™ Joined: Nov 2006 Location: Arkansas Oddometer: 12,718	Very nice bike!

12-22-2010, 02:41 PM	#24
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	The stock chain guide is fragile. A replacement from Procycle and I added a brace on the inside too. Bolted to the inside of the swingarm with nutserts. __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-22-2010, 02:43 PM	#25
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	The FMF header makes a difference. Fastway pegs I like, and the mount is cut down and rearset. __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-22-2010, 02:44 PM	#26
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	The seat is stock with a Yamaha XT600 foam added in, and the sheepskin too. Better for my bum and dodgy old knees. __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-22-2010, 02:45 PM	#27
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	The Megacycle muffler The racks are work in progress. __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build BergDonk screwed with this post 12-22-2010 at 11:15 PM

12-22-2010, 02:48 PM	#28
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	The main rack is an old Ventura that I've adapted. The toolbag is a Kelly The lower rack is from the wife's KLX250 and replaces the stock tailight. The replacement tailight and guard extension is Berg one I had lying about. __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-22-2010, 02:50 PM	#29
BergDonk ^OP Beastly Adventurer Joined: Nov 2010 Location: Snowy Mountains Oz Oddometer: 1,637	OK, so I seem to have the picture thing working now. Enjoy. More to come, I might have the shock tomorrow. Steve __________________ shed time IS quality time Check my DR650 story: BergDonks DR650 Build

12-22-2010, 02:56 PM	#30
tdrrally Beastly Adventurer Joined: May 2008 Location: doing hard time in charleston,wv Oddometer: 2,851	very nice it looks like you sail around the horn with that front end __________________ 2002 DRZ250 what it lacks in horse power it makes up for with traction for sale 2000 DRZ400e tagged 1980 TS125 project in the corner 200? zuma 50/70 the wifes bike

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