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Old 06-02-2012, 09:19 PM   #5641
bross
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Location: Osoyoos, BC
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Thanks. Can anyone else confirm?
Definitely runs in oil, just like just about every other motorcycle does. Only ones I can think of that don't are BMWs and the new Triumph Tiger 1200.
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Old 06-02-2012, 09:29 PM   #5642
Sateev
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Trailtech Vapor Speedo/Tach

Well, finally finished my Trailtech Vapor install, after living with a cold-blooded speedo for what seemed like forever. I'm happy with the results, learned a lot doing it, and no worries about changing front tire sizes: I can re-calibrate it with a couple of button presses...

To give a bit of background:

My old speedo was sticky: it wouldn't move off zero, unless it had been sitting in direct sunlight for a few minutes, despite the fact that it is normally 32-40 degrees C here in Bangkok. I wanted a nice electronic speedo, but didn't want a Mickey Mouse ignition mount tab leaving the switch highly exposed. Additionally, I wanted a 12V power port (Powerlet!) to power my GPS, and the whole thing had to look somewhat neat.

So, I decided to design my own mount.

I found a great (if somewhat pricey) service called emachineshop.com. They have easy-to-use CAD software that will not only let you easily design parts, but will render them in 3D, check their manufacturability, and quote prices for the part.

Here's the final design:


The hole with the keyway accepts the stock ignition switch, which snaps in place. The hole to the left is for the Powerlet Low-profile 12V power socket, The four mounting holes are secured by the four handlebar clamp bolts, and the two holes at the business end match the rubber grommets supplied by Trailtech in their mounting kit for the speedo. The hole on the tab (originally bent 90 deg.) is for a threaded insert, which accepts a screw through the number plate. It turned out to be unnecessary. More on this later.

The material I chose is 6061-T6 aluminum, .125" thick, with a mild brushed finish, because it is tough, and very machinable. I could have saved a bit by going with 5052-T5, but I HATE that stuff. It's soft, greasy-feeling, and I DON'T LIKE IT! Grabs drill bits, and tries to yank the drill from your hands. Yech!

Here is a picture of the bracket, before anodizing (and before I trimmed the tab off):



Here's a side view of the bracket I had to tweak (note the tab is bent at about 105 degrees, and the threaded insert is in place), next to the raw, un-tweaked bracket:



I originally wasn't sure how stiff the bracket would be, and whether or not it would vibrate with the weight of the speedo and indicators out on the end, so I designed it with a third mounting point, the tab, just in case. Since I used paper dolls to model everything for fit, I misjudged the angle, and had the tab bent to 90 deg., when it really needed to be 105 deg. Turns out to be quite stiff, though, so it's not worth having to drill a hole in the number plate for the extra mounting point.

I just lopped off the end.

Here's what the bracket SHOULD be like, without the tab:



I sent the trimmed bracket out for anodizing (gold color) to a local shop.

After re-wiring the indicator lights on the Trailtech bezel to plug into the stock harness, and running wires for the 12V Powerlet, I assembled everything. I used slightly longer stainless hex cap screws for the handlebar clamps, to allow for the extra thickness of the bracket, and used a bit of anti-seize to prevent galling.

Here's the result:



With the brake hose and speedo sensor wire held out of the way:



Showing the cable/hose routing:



The weatherproof lid of the Powerlet socket:



(The plastic hose on the crossbar is the 'friction mount' for my Garmin GPS62s GPS bracket)

I had intended to use a very slick sensor, made by Acewell, which would bolt directly into the speedo gear housing on the front wheel, but it is a different type of sensor (Hall), where the Trailtech uses a reed switch and brake rotor bolt magnet. I have designed an interface black box for the Acewell sensor, and when all the parts arrive, I will see if it works.

For now, I just lopped off the fitting from the stock speedo cable, filled the hole, and put it back to keep dirt and water out. Nothing wrong with the reed-switch, but I would prefer that the cable runs in the stock location...

So, that's it - it works. I still have a bit of tidying up to do (the flap that covers the wiring under the number plate has lost all it's velcro, and the wires are a bit too visible).

I won't cover the wiring here, except to say that the indicator lamps supplied with the Trailtech 'dashboard' (optional accessory) are disappointingly wimpy, even with the supposedly brighter LEDs that they supply. I even got some super-bright, triple-LED replacements, but it's still too dim in the daytime. I might have to do a re-design to mount my own indicators, but not anytime soon. If anyone else wants to try this, please PM me AND post here, and I will try to help with the wiring.

The Vapor unit itself is pretty cool, easy to set up, and has a lot more features than I will actually use. Things like shift lights, max temp recording, max rpm recording, max speed recording, etc.

I'm still diddling around with getting the tach to work properly, and haven't installed the temp sensor permanently, but it's all coming together.

At least I know how fast I'm going...

Note: no Suzuki wiring harnesses were harmed in the production of this modification.

Have fun.

Sateev screwed with this post 06-02-2012 at 09:36 PM
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Old 06-03-2012, 06:02 AM   #5643
MorganSS
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Sateev why dont you post some cool pics from the area you live? I like stuff like that.
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Old 06-03-2012, 06:03 AM   #5644
MorganSS
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Location: Kerrville Texas
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Quote:
Originally Posted by JayGoldstein View Post
Came upon this turtle sunning itself right in the middle of the dirt road. I moved it out of harms way. I couldn't tell if it appreciated my help.

From 2009 Suzuki DR200SE

usually they thank you by pissing all over your hands when you touch them lol

I will always try and help a turtle across a street, but then I go to my parents lake house and shoot them with pellets because they are harmful to the bass. Go figure.
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Old 06-03-2012, 07:37 AM   #5645
ben2go
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Location: Upstate SC USA
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Quote:
Originally Posted by BC1 View Post
Thanks. Can anyone else confirm?
All Suzuki charging rotors run in oil.No issue.It helps to oil the starting gears and starter clutch.
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Old 06-03-2012, 04:11 PM   #5646
bross
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Location: Osoyoos, BC
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Quote:
Originally Posted by Sateev View Post
Well, finally finished my Trailtech Vapor install, after living with a cold-blooded speedo for what seemed like forever. I'm happy with the results, learned a lot doing it, and no worries about changing front tire sizes: I can re-calibrate it with a couple of button presses...

At least I know how fast I'm going...

Note: no Suzuki wiring harnesses were harmed in the production of this modification.

Have fun.
Very clean, nice job! That link to the machine shop could cost me some money.
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Old 06-03-2012, 07:06 PM   #5647
Sateev
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Quote:
Originally Posted by bross View Post
Very clean, nice job! That link to the machine shop could cost me some money.
Thanks, Bross.

Emachineshop.com is pretty cool. If you're just making one part, it's kind of expensive, granted, but not that much more than if you went to a shop (including set up time). The software is so slick, however, with the ability to make changes easily, print out at 1:1 so you can make paper dolls to try, and to render the design in 3D, with rotate, that, for me, it made up for the cost. Also, if you make more parts, the cost per part goes down quickly, since most of the price is set up. (I made 4 brackets). They also have an online store, where you can put your creations up for sale.

Have fun.
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Old 06-04-2012, 11:47 AM   #5648
bross
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Location: Osoyoos, BC
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Quote:
Originally Posted by Sateev View Post
Thanks, Bross.

Emachineshop.com is pretty cool. If you're just making one part, it's kind of expensive, granted, but not that much more than if you went to a shop (including set up time). The software is so slick, however, with the ability to make changes easily, print out at 1:1 so you can make paper dolls to try, and to render the design in 3D, with rotate, that, for me, it made up for the cost. Also, if you make more parts, the cost per part goes down quickly, since most of the price is set up. (I made 4 brackets). They also have an online store, where you can put your creations up for sale.

Have fun.
That's very cool and once you make the part, that makes it so simple to crank out extra's for someone else wanting the same part.
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Old 06-05-2012, 01:09 AM   #5649
Klay
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Old 06-05-2012, 01:10 AM   #5650
Klay
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Old 06-05-2012, 05:57 AM   #5651
Bud11
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New tires? I need to replace my stock tires with some knobbies on my 2002 DR200. What are you running and what sizes? Thanks. Bud
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Old 06-05-2012, 07:24 AM   #5652
Wallrat
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110/90-18, thought they were TR8's but IRC does their sizes in imperial. Maybe a D745 non-DOT?
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Old 06-05-2012, 09:59 AM   #5653
Klay
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Maybe a D745 non-DOT?

This.
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Old 06-05-2012, 12:47 PM   #5654
Wallrat
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I'm not that good, I just know how to use the forum search hehe.
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Old 06-07-2012, 12:29 AM   #5655
tomas377
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new to this and need some advice on my dr200

short introduction
hi im tomas i got my dr200 bout 2 months ago and this is my first motorcycle and im using it currently for going to school and running around town. Im from the houston area also.

pros/why i got it
its small nimble and since i used to ride dirt bikes not total unfamiliar territory and it can go offroad and since im an outdoors guy this was a big plus.im 20 and about 5'8'' and 130lbs and didnt find any other dual sports that i was comfortable on with it also being a first bike.and i really like suzuki(also used to ride a rm250.

cons
because of the size and weight highway use isnt what i wish it was and model specific after market stuff are hard to find. and the sound lol i kinda wish it was more warmer and deeper.

the only customizing ive done to the bike are adding a black tinted slipstreamer windshield and trackside hand guards.

now some advice/questions

when adding the hand guards i found out they plugged the ends of the bars so i used a 9/16 on the ends so i could get the bar end mounts which was a pain in the ass attached.now my throttle feels a little lighter but if i let it go from being open about 1/2 way it stays there unless i physically close it. i never just let my throttle go but i just dont really like the feel of it.im thinking about changing the bars out since i dont like them that much anyway.

Are there and weighted bar ends i can use with some aftermarket bars that i can also use along with the hand guards that bolt into the end??? you know to clean up the look at have the throttle smoother.

also what are some stuff i can do to make my DR more highway friendly? im open to as much ideas as i can get no matter how small and miniscule lol.

also whats some stuff i can do as far as lighting to help it be more visible at night?ideas?

and other than manracks and happytrails what are some other options for luggage?

btw my bikes an 09 first owner
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