ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 02-26-2012, 06:16 PM   #1
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Will's DR650 funster project

Hey all. I've had a few other bikes, and I always benefit immensely from the big ole pile of info on all the forums. So I figured for my first off-road-capable bike, I'll take pictures of everything and document all the work. Maybe others looking for mods and farkles will happen on some useful details here.

In any case, I'm looking to build up a general allarounder, something I can take on the fire roads and the occasional tougher stuff, as well as on all the back roads of VA/MD/WVA/PA that I love so much. And I want to do some camping. Something cheap, fun, a bit of a change from my heavier road bike. After a bit of research, a DR650 seemed like the perfect choice -- cheap, bulletproof, fun enough, capable of highway cruising as well as the offroad work.

Here's what it looks like as purchased; good deal from a nice guy in a small town on a like-new 2009.





More to come.

** UPDATE ** A "most recent" pic so you get an idea of whats in the thread:


willmeyer screwed with this post 05-20-2012 at 04:24 PM Reason: added final pic at end
willmeyer is offline   Reply With Quote
Old 02-26-2012, 06:22 PM   #2
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Supermoto front fender

First things first, opened up the front to get ready for some wiring, and put on a new Acerbis supermoto front fender. Just a generic one but easy enough to drill for proper fitment.



willmeyer is offline   Reply With Quote
Old 02-26-2012, 06:29 PM   #3
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Tail tidy / fender eliminator

Wanted to clean up that gross rear fender and tail light, so got a DRZ 250 tail light and a license plate bracket from procycle. I should have just fabbed a bracket myself once I saw how simple this procycle unit is, but oh well, not a huge deal.

I like stainless socket head bolts, I generally replace every bolt I touch with them. You know, for more horsepower.



willmeyer is offline   Reply With Quote
Old 02-26-2012, 06:31 PM   #4
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Stainless socket head bolts

More stainless socket head bolt upgrades. Why not? And oh by the way I love boltdepot.com.

willmeyer is offline   Reply With Quote
Old 02-26-2012, 06:40 PM   #5
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Cycra hand guards

The hand guards that come stock on the DR650 are kind of a joke. Perhaps they'd protect from some light foliage, and they keep a modest amount of wind off, but otherwise they're not of much use. Plus they look pretty weak -- I wanted something more substantial. I had already decided on ProTaper Contour bars in the Carmichael bend, with ProTaper oversized clamps. So those went on nicely, and I was ready for a guard upgrade.

I went with guards and mounts from Cycra Racing, and I like the way they came out. Not too much trouble with the fitment, though with tapered bars its always a bit of a tweak. I used the U style clamps, which are nice in that they allow for easy cable routing on the bars. Here are a few pics:









willmeyer is offline   Reply With Quote
Old 02-26-2012, 06:55 PM   #6
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
LED signals

Wanted to go with lower-wattage LED signals, and had a model that I had used before on another bike. These "force" signals, cheap but work great, they have a yellow tip so the side visibility is great, which I like.

I fabbed up some little brackets to mount them on the rear, since I've removed the rear rack for now. Wiring was straightforward, I'm using a flasher from custom led, which I like generally. Its got a bunch of variable patterns as well as the standard dot flash. I pulled out the single indicator bulb in the dash for now, but I'll wire in some diodes to prevent the four-way flash problem when I get around to it. A few pics:





In this pic you can see the replacement cowl I put on as well -- if you can't tell, I'm converting the plastics to white:



willmeyer is offline   Reply With Quote
Old 02-26-2012, 07:50 PM   #7
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Stainless socket head bolts

Did I mention I like stainless socket head bolts?



willmeyer is offline   Reply With Quote
Old 02-26-2012, 07:54 PM   #8
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Moose racing fork skins

Installed some Moose Racing fork skins, the long variety. Had the forks out of the triples for other reasons, seemed like a good time to do it.

willmeyer is offline   Reply With Quote
Old 02-26-2012, 07:57 PM   #9
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Choke relocation

The OEM bike has a choke lever on the light/signal/horn switch, but as part of cleaning up the switch area I wanted to relocate the choke down to the carb area, a normal choke pull knob. I got the lever from Keintech, simple little mod.



willmeyer is offline   Reply With Quote
Old 02-26-2012, 11:14 PM   #10
eakins
Butler Maps
 
eakins's Avatar
 
Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 17,523
rock on
__________________
Butler Maps - motorcycle maps for riders by riders -
Alaska
AZ map COBDR AZBDR IDBDR South East map
http://www.advrider.com/forums/showthread.php?t=598717
Butler Maps website:
http://www.butlermaps.com
eakins is offline   Reply With Quote
Old 02-27-2012, 02:54 AM   #11
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
Tiedown points

For those times when you need something to secure a tiedown to...I got an overpriced bracket from "man racks". Not a great name, not a great website, and hey, its just a lasercut bracket. But whatever, in theory it'll be useful.

willmeyer is offline   Reply With Quote
Old 02-27-2012, 06:02 PM   #12
willmeyer OP
Geek
 
willmeyer's Avatar
 
Joined: Jan 2012
Location: DMV
Oddometer: 32
TrailTech Vapor gauge installation and setup

Ok, time to set up the TrailTech Vapor gauge. Seemed to be a popular choice, I went with it for three reasons:
  • I was going with some alternate wheels, and would need to change the speedo anyway
  • The stock speedo, even with a speedo gearing change, seems to be off non-trivially
  • Highly recommended here and elsewhere
First I wired up the tach pickup wire -- 5 coils around the spark plug wire near the coil. I settled on 5 after trying a few different wraps and experimenting with the stability of the measurement -- giving a solid reading while not varying up and down all that much. I taped it up with gaffer tape (my favorite) and some loom.



I then mounted the temp sensor under the outboard spark plug. I did have to dremel the tip a bit to get it to fit nicely without getting too mangled, as the ring is a bit larger than the hole into which it needs to fit.





So all together, nice loomed up wiring (I'm anal about getting it clean looking).



Then I moved onto the speedo sensor. For the magnet on the wheel, I used the magnetic head bolt that came with the Vapor kit, and ground it down to form a round plug that I could fit into one of the rotor rivets, with a nut on the back to increase stability. I then JB Welded it into the rivet, giving it two applications with a good long night of set time between.







For the sensor, I drilled into the caliper bracket (while off the fork) and used a self-tapping screw to mount it just inside. Tried for a while to figure out a way to do this that didn't involve this kind of positioning, but int he end it worked out just fine once I resigned myself to tapping it right into the bracket. Having the wheel off during this really helped, though was by no means necessary.





Now on to the dash...this required a little more thought. I wanted to have a powerlet plug up there, and of course to mount the Vapor. After going back and forth on all kinds of configurations, I settled on a very simple setup that involved two aluminum brackets I whipped up. This gives me a nice secure mount for the Vapor as well as a powerlet port, both positioned nicely and maintaining the stock ignition and indicator strip. I will probably move those eventually, but for now I kept them where they were to minimize rework.

Here's how that all came together.









So all in all, the Vapor came out great -- need to put some miles on the thing to really test out the setup, but I'm pretty happy with where its at right now. I'll get the bracket powdercoated once I finish some other fab stuff and have a batch of parts ready.
__________________
Geek dadz FTW!
* My DR650 mods thread
* My moto hacking pages
willmeyer is offline   Reply With Quote
Old 02-28-2012, 05:49 AM   #13
mega-hertz
creature of the wheel
 
mega-hertz's Avatar
 
Joined: Jun 2009
Location: circle city,ca(home) afghanistan, (work)
Oddometer: 77
awesome
__________________
DR 650se
anyone can piss on the floor, but a real hero shits on the ceiling!
mega-hertz is offline   Reply With Quote
Old 02-28-2012, 06:02 AM   #14
Black7
Adventurer
 
Joined: Feb 2012
Location: So. Indiana
Oddometer: 45
While I'm really diggin' the enthusiasm and your choice of mods, I'm thinking you will want to rethink those rear tails if you take it off-road. They look prime for being ripped off by a tree limb or thick brush, not to mention if you go down. Just a thought.

Nice job!

Oh, and yes its laughable how bad the stock speedo is at estimating within about 20%, your speed.
Black7 is offline   Reply With Quote
Old 02-28-2012, 06:29 AM   #15
Olas
the darkness
 
Olas's Avatar
 
Joined: Aug 2007
Location: Englewood, CO
Oddometer: 3,915
Quote:
Originally Posted by Black7 View Post
While I'm really diggin' the enthusiasm and your choice of mods, I'm thinking you will want to rethink those rear tails if you take it off-road. They look prime for being ripped off by a tree limb or thick brush, not to mention if you go down. Just a thought.
How so? This set up looks like it's much more tucked away from harm's reach than the stock unit. I like the clean, dirt bike look to it but what about the license plate light? I guess it doesn't matter unless you're riding at night.
__________________
Rebuild threads:
'92 XT600, '87 XR250R
Lighten up, Francis.
Olas is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 03:25 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014