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Old 05-04-2011, 03:59 PM   #151
Bushmechanic
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Hi Steve,

My wife allways looks at me funny if I tell her my bike is ready to go.. shes right a good bike project is never really finished :)

Ive seen bad die casting of bearing housing bores in cr500s cases, clutch side gearbox bearings with play.. nasty!

I like the 641 its good stuff and you can fix the bike on the road with bearings from a shop, if it doesn't work out in the long term though you could probably bore the hub +0.5mm then grind down the OD of the bearing a tad and run a sleeve over it ?
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Old 05-05-2011, 04:26 PM   #152
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Quote:
Originally Posted by Bushmechanic View Post
Hi Steve,

My wife allways looks at me funny if I tell her my bike is ready to go.. shes right a good bike project is never really finished :)
Ahhhh Bushie, she is a wise one, hang on to her. Nothing is ever finished, everything is only ever transitory.......

Steve
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Old 05-06-2011, 04:37 AM   #153
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Quote:
Originally Posted by BergDonk View Post
Ahhhh Bushie, she is a wise one, hang on to her. Nothing is ever finished, everything is only ever transitory.......

Steve

She is good indeed bushie. Wonder if my boss would have the same appreciation for this entirely sound philosphical approach....

Got to get out before you head off Steve, maybe a sneaky trip during the week. Have managed to drag Smithi back home for a second dose of Snowy too, so you'll need to put the billy on if we can't make a ride!
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Old 05-07-2011, 02:45 PM   #154
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Quote:
Originally Posted by nolana View Post
She is good indeed bushie. Wonder if my boss would have the same appreciation for this entirely sound philosphical approach....

Got to get out before you head off Steve, maybe a sneaky trip during the week. Have managed to drag Smithi back home for a second dose of Snowy too, so you'll need to put the billy on if we can't make a ride!
I hope Smithi still has a bike with knobs on it ,my sources have it that he has been spending time on the tar

Steve has always got time in retirement land unlike some of us that still need to slave away in Snowy land

cheers
Scott
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Old 05-08-2011, 03:07 AM   #155
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I hope Smithi still has a bike with knobs on it ,my sources have it that he has been spending time on the tar

Steve has always got time in retirement land unlike some of us that still need to slave away in Snowy land

cheers
Scott
Your sources are accurate Scott, he's shod only with very smooth rubber. I've already gone to work on him though and he has plans hatching to correct the situation as I type!
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Old 05-08-2011, 04:35 AM   #156
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Laugh

Quote:
Originally Posted by nolana View Post
Your sources are accurate Scott, he's shod only with very smooth rubber. I've already gone to work on him though and he has plans hatching to correct the situation as I type!
good to hear

wouldn,t want the enviroment to miss out on a set of nobbies carving up this great land of ours


cheers
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Old 05-20-2011, 11:22 PM   #157
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I got asked about the fuel plumbing. I got a servicable filter from ebay:
http://shop.ebay.com.au/i.html?_nkw=....c0.m270.l1313

After a couple of goes, its now set it up so the lines either go up to a fuel tap, or the carb, so no air traps and blockages at low fuel levels which happens with the Safari at low levels. All plumbing is 8 mm or 5/16 to reduce head loss and the u turn at the bottom of the filter is a piece of copper tube carefully bent with a spring bender. All other filters removed, ie from inside the fuel taps, and if I still had the BST40, from it too. The FCR has a rotating inlet pipe so all angles are possible. With a horizontal filter it looks tidier, but the filter gets air blockages. If the fuel stops flowing, there is only one filter to check. Works good now.

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Old 05-21-2011, 01:47 PM   #158
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Originally Posted by BergDonk View Post
I got asked about the fuel plumbing. I got a servicable filter from ebay:
http://shop.ebay.com.au/i.html?_nkw=....c0.m270.l1313

After a couple of goes, its now set it up so the lines either go up to a fuel tap, or the carb, so no air traps and blockages at low fuel levels which happens with the Safari at low levels. All plumbing is 8 mm or 5/16 to reduce head loss and the u turn at the bottom of the filter is a piece of copper tube carefully bent with a spring bender. All other filters removed, ie from inside the fuel taps, and if I still had the BST40, from it too. The FCR has a rotating inlet pipe so all angles are possible. With a horizontal filter it looks tidier, but the filter gets air blockages. If the fuel stops flowing, there is only one filter to check. Works good now.

I will have to try a loop down from my T join and back up to the carb inlet. Mine sucks air and will not go to reserve without getting an airlock. My plumbing is basically horizontal at present. Thanks for posting the "fix"
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Old 05-21-2011, 03:57 PM   #159
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I love heated grips, and it was one of the first things I did to the DR after I got it. The 2 speed type that wrap around the bar and then you fit normal grips over the top in this case. Unfortunately after playing with the wiring of my lights, GPS, power extras and the forks on and off a few times, the resistor that is switched into the circuit for the low heat setting broke. It's been suggested a more efficient way to wire up the grips would be to have them in series for the low setting rather in parallel with the series resistor. I thought this was a good idea, thanks Ash, and came up with the following circuit which uses a DPDT centre off rather than the stock SPDT centre off.

No heat loss from the restistor, so more watts for something else on low setting, and one less thing to break again.

FWIW



Steve
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Old 05-21-2011, 04:26 PM   #160
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Quote:
Originally Posted by Phreaky Phil View Post
I will have to try a loop down from my T join and back up to the carb inlet. Mine sucks air and will not go to reserve without getting an airlock. My plumbing is basically horizontal at present. Thanks for posting the "fix"
The main thing is that there are no high spots that do not go directly to the carb or a tap. Air is 'sticky' and if a bubble forms it'll stick to the side of the rubber hose. When the fuel level is low, and in the Safari it gets very low relative to the carb float bowel, there is not enough pressure to break the air bubble stiction, so the idea is to eliminate anywhere a bubble can form, and the low bits under the carb fuel intake pipe will always have fuel in them. Seems to work.

Steve
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Old 06-29-2011, 07:43 PM   #161
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Not a ride report, but a DR report.

I got to the centre and back unscathed. Missed the Kimberly this time as I had to get back a bit earlier than initially planned for domestic reasons. The KTMs and XR are still out there.

Still managed nearly 7,000 kms though. Bit of a trip log below. Most days were via the more interesting route option, but some parts required bitumen because dayight was getting short. It was interesting to note the traffic density vs road kill density in places, especially NW NSW, scarey...

Centre Trip Log
Day
Start trip meter
Finish trip meter day dist total dist

02/06/2011
Numeralla 22410
Narranderra 22881 471 471

03/06/2011
Narranderra 22881
Wentworth 23394 513 984
2 broken spokes, flat tyre
04/06/2011
Wentworth 23394
Yunta 23763 369 1353

05/06/2011
Yunta 23763
Blinman 24105 342 1695

06/06/2011
Blinman 24105
William Creek 24544 439 2134

07/06/2011
William Creek 24544
Mt Dare 25010 466 2600
finished 3.5 kms short
08/06/2011
Mt Dare 25010
Kulgera 25010 0 2600
trailer trip
09/06/2011
Kulgera 25010
Alice Springs 25010 0 2600
clutch replacement + 2 oil changes
10/06/2011
Alice Springs 25010
Alice Springs 25010 0 2600

11/06/2011
Alice Springs 25010
Alice Springs 25010 0 2600

12/06/2011
Alice Springs 25010
Alice Springs 25010 0 2600

13/06/2011
Alice Springs 25010
Glen Haven 25238 228 2828

14/06/2011
Glen Haven 25238
Kings Canyon 25468 230 3058

15/06/2011
Kings Canyon 25468
Yulara 25792 324 3382

16/06/2011
Yulara 25792
Yulara 25792 0 3382

17/06/2011
Yulara 25792
Cadney Homestead 26376 584 3966

18/06/2011
Cadney Homestead 26376
Leigh Creek 27033 657 4623

19/06/2011
Leigh Creek 27033
Innamincka 27580 547 5170

20/06/2011
Innamincka 27580
Tibooburra 27951 371 5541

21/06/2011
Tibooburra 27951
Wilcannia 28310 359 5900
oil change
22/06/2011
Wilcannia 28310
Temora 28907 597 6497

23/06/2011
Temora 28907
Numeralla 29247 340 6837
broken speedo cable

The DR ran great the whole trip. There were 3 others along and comparisons, especially fuel consumption, were interesting, and for me provided validation, especially my suspension and ergos.

My flat tyre was interesting. I was 'racing' ahead on the Hay plain late in the afternoon to sort accommodation in Wentworth when that wobbly feeling suggested a stop was required. The tyre was very, very hot, and flat. The patch on the tube that'd been OK prior had partially peeled off, probably causing a slow leak intially. What took me by suprise though were the 2 broken spokes. My theory is that the aluminum rim grew a bit from the heat and the spokes snapped off at the head in the hub where they've been peened over and the likely stress concentration makes that the weakest bit. Maybe I build my wheels a little too tight. I had a few spare spokes, so fixed easily enough and I backed all the other nipples off a 1/8 turn. Dunno, but OK subsequently.

Heading into Mt Dare from Dalhousie Springs I was a bit behind the bike pack. Been rubber necking with the 4wds. But it was raining and I was now over 1/2 and hour behind the other bikes, and that was too much rain because I got stuck in the glutinous mud with the rear end locked solid. What I thought was wheel spin was actually clutch slip. 3.5 kms short of Mt Dare in the dark and rain, and no drive, bugger...

I had among other bits and bobs a clutch kit in the 4wd support, so I wasn't too concerned, but what was an issue was the continuing rain and impending closure of the roads which would mean we'd be there for a while. So I purchased the trailer they lent me to recover the bike, and we headed for Kulgera the next day early, 280 kms to the bitumen via a 250 km bog hole and constant rain. I must admit I wasn't totally unhappy to be in the 4wd. There were a number of crashes, and speed and momentum were necessary. Travelling at 100 kph and sliding from one side of the road to another in a constant state of almost crashing is not only physically challenging, but more so mentally. Kudos to the guys who all rode out.

Apart from the clutch, I also noted that my bash plate had separated from the frame. The stock tabs on the back of the frame had fatigued and fallen off, so it was strapped up whilst on the trailer. Corrugations, case outs? Managed to get it all welded up and strengthened in Alice on the Friday afternoon just before the long weekend, and with a new clutch and a couple of oil changes, good to go again. The Finke Desert Race we were there to check out meant it was very busy in town, and everyone was getting ready to party. If it didn't happen then, it have to wait until Tuesday otherwise.

The only other issue with the bike was a broken speedo cable on the last day.

FWIW the fuel consumption of the DRs was something like:
Ray 20 km/l - Megacycle muffler, stock header, Dynojet kit, cut airbox
Me 19 km/l - Megacycle muffler, FMF header, 39 mm FCR MX, cut airbox
Ash 17.5 km/l - TK pipes muffler, stock header, Dynojet kit, cut airbox
Dave 15 km/l - Full Staintune, stock carb and airbox, with snorkel

I reckon with my extra frontal area with the tank panniers makes up for a bit too. Ash used to get better economy, but then he opened up the airbox some more just before the trip. Too much of a good thing?

Dave was getting about 10 km/l on the first couple of days having paid a mechanic to tune the carb before the trip. We did a couple of morning carb strips on the first 2 days out on Dave's bike to get it as good as it now is. The fuel running out the carb body at the servo in Naranderra the first morning out was a clue.

The only other DR issue was broken tabs on the subframe from the rack on Ash's bike. Fixed with zip ties and hose clamps on the road.

The rear Mitas E07 with 1,500 kms on it when I started off now has about 8,500 kms on it and probably will go another 2,000 kms before I change it. OK everywhere, but not very good in slop, but a fantastic all rounder. The fresh E09 I had on the front is all but worn out, and I won't use them again. OK, but prefer a bit more knob like an MT21. I have an E09 to try on the back next.

As I didn't get as far as I wanted this time, gotta go again sooner. The bike is ready and up for it, and so am I, and I have unfinished business outback.

Steve
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Old 06-30-2011, 12:09 AM   #162
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Sounds like a Hell of a ride Steve. Congrats on getting back OK!
Mud riding is tough ... would full knobby tires have helped you out any?
Those 50/50 Mitas are good, long lasting tires but not much good in sand or mud, eh?

Surprised you lost your clutch ... but I guess having the rear wheel locked and not knowing it ... not good. With a good knobby I find that if I can manage some speed once in a while, I can fling off built up mud. But sometimes the mud is just too sticky.

I remember early in the thread you mentioned:

"I acquired a clutch cover gasket just in case, but the original came off clean so its been recycled. The clutch friction plates looked fine, and measured to spec. The steels were somewhat blue, so been hot in the past. Works OK, so until next time."

Only thing I can think of regards repeated hub bearing failure is alignment issues. Bent axle? Tweaked Swing arm? Messed up Hub? All of the above?

We haven't heard about too many hub bearing failures on the BIG DR thread, mostly from you Aussie guys. But you guys ride hard in harsh conditions. We Americans just ride 50 mph with the Harley guys on straight, smooth roads.

I have two sets of wheels for my mostly stock DR. One set:40,000 miles,
and a set from a '97 with 32,000 miles. All bearings "feel" just fine to me. I keep checking them and expecting them to fail or fall apart.

I've never done many deep water crossings or Ocean/Beach/sea water riding, but plenty of Desert and high mountains. Still ... will definitely be carrying spare wheel bearings along on longer international rides.

Curious where you guys slept. Bush Camping? Did you carry cooking gear? Beer? What was the longest stretch between fuel/water stops? Did you have bail out points to get to a town if you had a problems or an injury? Must be nice to have 4 wheel support. What a luxury!
Did they follow along with you or take different paved routes and meet you?

do you guys take pictures?
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Old 06-30-2011, 05:55 PM   #163
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Hi Grifter,

Some brief backgroud, and then some specific answers.

Detailed planning for the trip started out about 18 months ago by Rowdy_IM and some other mates from Jindabyne. 1 x 4wd and 3 x bikes. I then joined in and a few of my mates from Canberra got involved too, so then I felt the need to increase the level of 4wd support, so another mate from Canberra and his partner in a 4wd and my wife in mine. With another bike joining in at the last minute we had 3 x 4wds and 8 x bikes, 1 x Mitsubishi Triton, 2 x Ford Couriers, 2 x orange 625s, 1 x 690, 1 x XR650 and 4 x DR650s. Another DR650 with dedicated 4wd support also joined in late, but then pulled out near the get go due to a death in the family, you never know...

The ride officially started at Blinman on 06/06, so it was optional how we got there. The 690 and DRs rode out, the others were more time poor so trailered. The plan was to head to Alice, check out the Finke Desert Race, then cross the Simpson to Birdsville where those with more time, Rowdy_IM, AdventureXR, myself on bikes and Moggy and Dad in his Triton would head for the Kimberly, and rest home.

With our experience of the western end of the Simpson getting to Alice, and the impossibility of a full crossing due to the flooding of Eyre Creek, we decided to split at Alice, and as stated before, I unfortunately had to join the early finishers too. We again split in Leigh Creek, as Dave, myself and wife Sandra still had a few more days available than the rest of the early finishers who had to beeline for home.

We were setup for most anything, and we carried all gear on the bikes other than some of us opted to have the camping stuff, including extra food, on the 4wds. I used a Exped mattress and Sac2 sleeping bag and had a Speedy popup tent to share with my wife in the 4wd, and a hiking tent on the bike for when/if we separated. The 2 Couriers were set up much the same. Both are Crew cab 2.5 TDs. I fitted upgraded and strengthened suspension, 160 litres of water, 140 litre diesel tanks, new mud tyres, sand flags, roll out awnings, full recovery gear etc etc. They both had over 240,000 kms and gave no problems.

We also had a training/practice day for the 4wds near here down in the river sand practising bogging and recovering the vehicles using sandtrax, and snatch straps etc. Good for the riders to know how to hook up a 4wd too, cause then they can help.

Each rider had a 900/550/400 space case on the 4wds for carrying their gear.


Sounds like a Hell of a ride Steve. Congrats on getting back OK!
Mud riding is tough ... would full knobby tires have helped you out any?
Probably, but then for the other 6,500 kms? I would like to try some others out there one day to find out.

The main problem I had when the clutch failed was vision. I was wearing my Arai DS and moisture gets on the inside of the visor when its cracked for ventilation. I switched to some industrial safety glasses, but they also became an issue. As vision deteriorates, speed reduces, and the tyres stop clearing, and it all gets worse. Once you have no eye protection, mud and rain is in your eyes, and the speed is less again, and its night and dark too, so picking the terrain is tricky. In daylight, the next day, other line/route options off to the side were apparent. And my HID and LED lights are great, but when there is nothing for them to reflect off other than rain drops, they don't solve the problem. If I know I'm going to crash, I prefer to do it slowly

Those 50/50 Mitas are good, long lasting tires but not much good in sand or mud, eh?
They are OK in sand and pretty much everywhere else too, but mud is definitely outside their design brief. They are nevertheless a great all rounder, and I will use them again. The life/value equation is fantastic, and I know of no better all rounder, but then I haven't tried them all either. I think that I'll stick to MT21s up front too. I have a 606 to finish off first, but I think I prefer the MT21 as an all rounder that still has some knob.

Surprised you lost your clutch ... but I guess having the rear wheel locked and not knowing it ... not good. With a good knobby I find that if I can manage some speed once in a while, I can fling off built up mud. But sometimes the mud is just too sticky.
This stuff is sticky......

I remember early in the thread you mentioned:
"I acquired a clutch cover gasket just in case, but the original came off clean so its been recycled. The clutch friction plates looked fine, and measured to spec. The steels were somewhat blue, so been hot in the past. Works OK, so until next time."
Perhaps the previously heated plates were almost dead. It was only one plate that lost its friction material, so I kept the rest just in case. I'll blame the previous owner of the bike for the previous clutch cooking And the original gasket is OK still too.

Only thing I can think of regards repeated hub bearing failure is alignment issues. Bent axle? Tweaked Swing arm? Messed up Hub? All of the above?
Agreed, but it all seems fine. I've checked the axle for runout, and considered ADV8s views too. Checked with and without rubbers, put new rubbers in etc. So far the double row bearing holds up fine, but its now at about the kms the originals failed at, so from now on is the test I guess.

We haven't heard about too many hub bearing failures on the BIG DR thread, mostly from you Aussie guys. But you guys ride hard in harsh conditions. We Americans just ride 50 mph with the Harley guys on straight, smooth roads.
Yeah, right.

I've done a couple of road trips in years past (on 4 wheels) through some of the western US, California, Utah, Arizona, Nevada, Colorado, and Idaho and played on some of your off road terrain. Beautiful country. One of my regrets, I think, was not taking up an offer of a free ride made by a tour company I bumped into in Ely Nevada one night in the mid 1990s. They offered me a DR350 and helmet, maybe gloves, for the following day but I had no other gear available, and I felt that to ride in the desert needed more, and I had to be at work in Denver in a few days, so

Your sealed roads are smooth though, one pothole seems to provoke a 100 km re-seal Often wished I had my road bike.

I have two sets of wheels for my mostly stock DR. One set:40,000 miles,
and a set from a '97 with 32,000 miles. All bearings "feel" just fine to me. I keep checking them and expecting them to fail or fall apart.
When I ride around here, it can be tough terrain. I have a 10 km single track in my yard, starting just outside my shed door, and then I have 100s of kms of fire trails and single track just outside my gate. Most people call the tracks here 'rocky', so all bits of bikes and bodies get a work out

I've never done many deep water crossings or Ocean/Beach/sea water riding, but plenty of Desert and high mountains. Still ... will definitely be carrying spare wheel bearings along on longer international rides.
My daily maintenance includes a wheel and cush bearing check. Just give them a twist, and you can do the cush by pushing the sprocket sideways with your foot if you want to keep your hands clean.

Curious where you guys slept. Bush Camping?
Bit of a mix, the odd motel, cabin, or camping in a van park, or just in the bush. We were equipped for a number of days without access to 'civilisation' if needed, but ahot shower at the end of the day for us old arthritic sufferers is nice if you can get it.

Did you carry cooking gear? Beer?
Mostly in the 4wds which all have fridges or coolers. A couple of the guys carry cooking gear on the bikes, but I can live without heating food or drink, so don't bother.

Temps were down to -2 degC overnight a few times, and daytime temps up to about 15 degC.

What was the longest stretch between fuel/water stops?
If we had done the Simpson crossing, its about 500 kms, and recommendeed to allow 600 kms for possible deviations.The biggest day I did between fuel availability was Leigh Creek to Innamincka, across the the northern Flinders to Mt Hopeless and up the Strezlecki. Still had 100 kms in the tank after 547 kms. Other big days without possible services in between were Wentworth to Yunta via Chowilla and Dangalli, a beautiful ride in the sand, at 369 kms and Yunta to Blinman at 342 kms. If I'd got to the Tanami, we needed to plan for 1,000 kms as the road house at Rabbit Flat is now closed. Some other possibilities perhaps, but I will find out what actually happened when Rowdy_IM and AdventureXR650 get home. I was planning to be with them, ah well.

Did you have bail out points to get to a town if you had a problems or an injury?
Sometimes yes, sometimes no.

Must be nice to have 4 wheel support. What a luxury!
Was great, especially as my wife was in one of them

Did they follow along with you or take different paved routes and meet you?
Mostly yes, but we had plans to separate hence all bikes and riders needed to be self sufficient.

do you guys take pictures?

Yep, will post some later.

I have unfinished business outback,
Steve
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Old 06-30-2011, 07:28 PM   #164
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Very interesting reading... both the ride and the lead up work on your bike. Thanks.

How did you find travelling with such a large group? (I find the pro's & con's to be - great fun around the campfire but too slow on the track)

I can relate to the night riding & mud saga and agree 100% with your comment "if I know I'm going to crash, I prefer to do it slowly". Coming off the bike during daytime riding is an 'if' state of mind for me... but with the combo of night + rain + mud/sand + goat tracks, my mindset seamlessly shifted to 'when'. Fortunately I didn't come off.

My mini report from a ride on the other side of the country around similar dates to yours http://drriders.com/topic874.html - second last post.

And, my DR story http://drriders.com/topic1140.html

Cheers
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Old 07-02-2011, 04:36 PM   #165
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Very interesting reading... both the ride and the lead up work on your bike. Thanks.

How did you find travelling with such a large group? (I find the pro's & con's to be - great fun around the campfire but too slow on the track)

I can relate to the night riding & mud saga and agree 100% with your comment "if I know I'm going to crash, I prefer to do it slowly". Coming off the bike during daytime riding is an 'if' state of mind for me... but with the combo of night + rain + mud/sand + goat tracks, my mindset seamlessly shifted to 'when'. Fortunately I didn't come off.

My mini report from a ride on the other side of the country around similar dates to yours http://drriders.com/topic874.html - second last post.

And, my DR story http://drriders.com/topic1140.html

Cheers

Big group? Yep, pros and cons. Fortunately we were/are pretty much all on the same wavelength, and chewing dust is not something any of us are keen on, so being strung out is OK, (and its only a race if you win!). Getting away in the morning is the hardest, but all we really needed to do was know what the day's route and target destination was. We might have a few regroups enroute, or just wait until the lunch stop or camp site. By pairing up, and all having UHF CBs it works OK. The 4wds don't travel too much slower and were never far away anyway. And being fully self sufficient, we could vary Plan A anyway as the day proceeded by applying Plan B. (FWIW Plan B is to change Plan A)

The rule of "more riders means a slower trip" nevertheless applies. The upside to our group was that everyone in the 4wds could ride if needed, and amongst our group we had 3 fitter/machinists, a diesel/plant mechanic, an electrician and handyman me. We figured if we couldn't fix it on the trail, it couldn't be fixed on the trail.

One of the connundrums we had is sight seeing vs riding. There is no doubt its easy when in the car to pull up somewhere and go for a walk to check something out. My Gaerne Adventure boots are good, and so much easier to walk in than my Tech 8s, but hiking up Standley Chasm, or around the Kings Canyon rim, or through the Olgas is so much easier in proper shoes without knee braces, and gear security is not an issue either. Is it the journey or the (multiple) destinations?

Seems we got caught up in the same weather front and our DR stories aren't too dissimilar either. Keep an eye on your rear bash plate mounts. I'm assuming yours is the first 'production' DR model? I've emailed Matt about mine, and its my recommendation that everyone be advised of the possibility of failure. In hindsight, I should have beefed them up before failure.

FWIW I got out yesterday on my 650 Berg with my brother on his XR400. I hadn't ridden it for a few months, and you forget. Compared to the DR, its a scalpel in the bush, and it'll kill you if you twist the throttle inadvertantly 63 hp at the knobs, and 122 kg wet will do that And the supension needs to hit stuff at speed to work

But the DR will go day after day after day with negligible maintenance, and the ergos mean that its comfortable to do it too. And the suspension compromise I've achieved means it can go slow, or fast and keep in shape. I even have to admit that its now more comfortable than my 1400GTR, aka Concours 14, with its own improved seat, for all day rides.

Steve
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