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Old 09-09-2012, 07:06 AM   #46
jdrocks
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what rate is your new spring? once done with this latest round of mods you'll be moving faster and still need some shock adjustment to avoid that interference issue. you need to free up that rear brake line in the guide.

the HEL lines are a good idea, but if you didn't order a HEL front line sized for the DRZ400, you'll find the Versys spec line too short for your new big boy DRZ forks. the stock DRZ banjo ends will work fine with your setup.

the adapter to mate the Versys/ER6 caliper to the DL1000 wheel/DRZ fork setup looks like this



several clearance issues, so you'll end up with a complex shape. these adapters are commonly fabricated in aluminum alloy, but i chose steel for this critical part. i suggest you check the ER6 forums and research the common 4 pot calipers that are swapped onto the ER6 bikes. the OEM Versys caliper provides very good braking with a 310mm rotor, but since you haven't fabbed an adapter yet, now would be the time to go 4 pot. the caliper is cheap on the used part market, and the adapter would look very similar.

front axle and spacers are easy.

you're going to wonder why you didn't mount those 49mm forks sooner.
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Old 09-10-2012, 08:08 AM   #47
kajj OP
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Thanks for the reply JD.

I have read somewhere on the versys forum that the OEM roadstar spring should be about 13kg/mm.
Don`t know if that is correct.

Why free up the rear brake line? it is not going to move in the guide anyway?

I have one Hel brake line that was supposed to go over the mudguard connecting the two original calipers that I
could connect to the longer one.

Yea that is a complex shape. I`ll see what I can come up with.

I will look into the 4 pot caliper swap. But at the moment I do find the braking power very good.
Especially with the Brembo brake pads.

I think I am going to use an M20 12.9 screw as a front axle, if I can find one in the correct length.
Also the seatpost at my bicycle has the correct inner and outer diameter to function as a sleeve for the front axle.
And an exhaustpipe cut to the right length will function as sleeves to mount the DRZ fork in the Versys clamps.
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Old 09-10-2012, 08:16 AM   #48
jdrocks
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Quote:
Originally Posted by kajj View Post

I have read somewhere on the versys forum that the OEM roadstar spring should be about 13kg/mm.
Don`t know if that is correct.
you'll find 13kg is too light a rate, even without panniers.

i have some 4 pot Tokicos, but haven't bothered to switch yet.
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Old 09-10-2012, 09:26 AM   #49
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Quote:
Originally Posted by jdrocks View Post
you'll find 13kg is too light a rate, even without panniers..
I have to disagree with that. I am not a big guy (72kg without gear) and running with minimal preeload right now.
And it seems to work just fine, no bottoming out yet.

Did a test run in an nearby sandpit two days ago, trails with rocks and roots, hillclimbs up a sandy sloop.
I don not now if i would like it to be any harder as it wouldn`t absorb much of the impacts on the rocky sections.

But time will tell.
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Old 09-10-2012, 11:33 AM   #50
jdrocks
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Quote:
Originally Posted by kajj View Post
I have to disagree with that. I am not a big guy (72kg without gear) and running with minimal preeload right now.
And it seems to work just fine, no bottoming out yet.
maybe it's not a 13kg spring.
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Old 09-10-2012, 11:47 AM   #51
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Quote:
Originally Posted by jdrocks View Post
maybe it's not a 13kg spring.
Maybe!

I do not really know what spring rate it is. There seems to be two versions of the "Roadstar" the XV1600 and the XV1700.
I have the spring from the XV1700, might be a higher spring rate then the one on the XV1600?
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Old 09-22-2012, 07:39 AM   #52
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Front wheel axle

I did manage to find a used swingarm bolt from a Kawasaki er6.
A spacer is needed on the left side. Hmm my bicycle saddle pole could be the right diameter.


Inner diameter: 24mm (Should be 20mm)
Outer diameter: 29mm (Should be 25mm)
Wall thickness: 2.5mm

Cut the pipe to the correct length and sawed a slit at one side.
Some work with the polygrip and a hose clamp and it now has an inner diameter at 20mm and a outer diameter at 25mm.

A perfect fit!





The threaded part need to be extended and the axle cut to the proper length.
That will have to wait until I can get hold of the correct die for the threads.
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Old 09-22-2012, 12:38 PM   #53
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Caliper adapter: Part 1.

I had some time over and decided to start with the process of designing a caliper adapter to be able to
mount the Versys caliper to the DRZ fork and the V-strom wheel and disc.

First of. To draw a simplified 3D model of the fork, wheel, disc, spacers and caliper.

All I had time with tonight was the right fork leg with the mounting points to the brake caliper and wheel axle.

This will finally result in a 2D drawing of the adapter and later a finished product.


To be continued.
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Old 09-23-2012, 02:13 AM   #54
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Caliper adapter: Part 2.

Front wheel axle, spacer and brake disc added to the front fork assembly.

I did say that it should be a simplified model. But it starts to look more like the real thing



Only front wheel, brake caliper and caliper adapter left. But those are mounted on the bike so that might have to wait until I bring the bike inside.

To be continued.
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Old 09-23-2012, 04:18 AM   #55
jdrocks
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Only front wheel, brake caliper and caliper adapter left. But those are mounted on the bike so that might have to wait until I bring the bike inside.
find a cheap used 310mm rotor.
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Old 09-23-2012, 06:51 AM   #56
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Quote:
Originally Posted by jdrocks View Post
find a cheap used 310mm rotor.
I will do a search and see how much they cost here in Sweden. Something tells me that they are expensive, as everything else here. And from the states I have to pay about 50 bucks in shipping.

Perhaps a cheap one turns up during the winter.
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Old 09-30-2012, 08:06 AM   #57
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Last ride

It is almost time to change the tires on the car to dubbed tires and the motorcycle season has come to an end.
But I manage to get out and ride one last time before it was time to bring the bike inside and to continue the build.

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Old 09-30-2012, 08:10 AM   #58
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the build continuous

So after removing the tank and fairing it was time to clean the bike before bringing it inside.
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Old 09-30-2012, 08:18 AM   #59
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KLR side stand

I will need a longer side stand when the DRZ fork legs are mounted.
After recommendations from JD I decided to go with the later model KLR 650 side stand which mounts directly to the original Versys mount.


But it need to be a bit longer. My old bent OEM Versys handlebar should be the right diameter to extend the side stand.



Mounted on the bike


The only thing left to do is weld and paint it. But that will have to wait for a while.
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Old 09-30-2012, 08:25 AM   #60
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DRZ fork legs

Time to mount the DRZ400 fork legs. These should bolt right in with a 2.5 mm sleeve at the lower triple mount and a 0.5 mm sleeve at the upper triple mount.





Damn this is one tall bike. 125cm to the handlebars and almost 150 cm to the top of the fairing
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