2000 F650GS Dakar - Break down and rebuild

Discussion in 'Thumpers' started by Aquatic, Nov 18, 2011.

  1. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    After having a Dakar in South Africa and sitting here in Australia for just over 2 years without a bike, I was going insane. And noticeably too. The Mrs said "You need to get another bike!"

    So I did!

    A 2000 Dakar. Pretty much exactly the same bike that I had back in RSA.
    South Africa
    [​IMG]

    Australia
    [​IMG]
    What can I say, I'm a sucker.

    Anyway only a couple of weeks after getting the new bike I took a new job and we up and moved from Brisbane south side up to the Sunshine Coast.

    All funds that I had put aside had to be reassigned to the move :(:
    Oh well, that's life!

    So GuS2 has been sitting in the garage tires and battery going flat. :cry:cry

    My birthday came along and my wish for a bike lift was granted.


    When I got the bike my mind started racing with ideas on farckles and mods.
    Unfortunately my current finacial situation does not allow for many of the mods I have in mind, so this will be a very 'Pooratech' rebuild.

    Who knows, I might just win the lotto down the line :evil

    So this is going to be a very slow process as I will be doing all the work myself.

    A big advantage of the new job is all the tools and machines available to use.
    CNC Mill
    CNC Lathe
    CNC Plasma cutter
    Guillotine
    Press brake
    bender
    roller
    TIG and MIG welding machines
    Plenty of Ally, Stainless and Acetyl off cuts
    Access to powder coating and laser cutting.

    A tinkerers wet dream!


    This is what I started with......
    [​IMG]
    On my new bike lift! Thanks Cherie and Jessie ;D

    This is the current state of affairs......
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
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    Just about all stripped down. Just the engine and wireing harness to pull out.


    Like I said this is going to be a time consuming process. Hopefully not too frustrating and very rewarding!


    Here goes.........
    #1
  2. divimon2000

    divimon2000 Been here awhile

    Joined:
    Apr 16, 2011
    Oddometer:
    637
    Location:
    Lake Champlain, Vermont
    Nice! I may be posing a couple questions your way as I'm doing the same here in the US. Bringing it back to life if you will. Glad I did, lots of loose parts, etc. Have fun mate.
    #2
  3. kubiak

    kubiak Long timer

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    Nov 25, 2007
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    4,837
    Location:
    madera california
    im watching this build!
    #3
  4. tmotten

    tmotten Lefthand ride Dutchy

    Joined:
    Jun 28, 2006
    Oddometer:
    2,614
    Location:
    Calgary
    Wow, it seems that rebuilding this bike is getting more and more popular. I'm doing the same things and I'm only just down the road from ya. Good find with the fork upgrade already done.
    #4
  5. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    4,912
    Location:
    Garden City, Michigan
    I'm curious, how many miles are on the bike, and what are your goals ??
    #5
  6. Benjah

    Benjah Been here awhile

    Joined:
    Jun 22, 2010
    Oddometer:
    175
    Location:
    Christchurch, New Zealand
    Why you take nice bike apart?
    #6
  7. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    Not quite 40000kms
    And all will be revealed with time:evil
    #7
  8. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    That is who I am!
    #8
  9. GAS GUY

    GAS GUY MILE EATER

    Joined:
    Jul 27, 2007
    Oddometer:
    4,912
    Location:
    Garden City, Michigan
    That sounds interesting, good luck, and I look forward to seeing it when its done.
    #9
  10. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    The most together part of the bike is the engine.
    [​IMG]

    I'm thinking I might just make a holding bracket and a stand so I can work on the engine with ease. I'll see what is lying around at work
    Things to check:
    Valve clearances
    Clutch
    Water pump gears.
    Possible improvements:
    New model oil return line replacement
    New model 2 piece clutch side cover - if I can find a 2nd hand one some where.

    I just need to prep the frame and then I will have all the powder coating parts ready.
    [​IMG]
    Frame, Sub-frame, Swing arm, Engine/Frame bracket, lower twin rail frame, sidestand, foot peg brackets and foot pegs, Crash bars and the other black frame bits will all be powder coated black.

    Some issues I picked up on while stripping down:

    Swing arm and linkages bearings and bearing races are all fukt!:(:
    [​IMG]
    [​IMG]
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    I went Coastline BMW to get prices for the linkage inner races. "(add expletive here)!" pure extorsion! Cheapest just over $20 and the dearest $35. I didn't dare ask the price of the swing arm bearing races.
    MAX BMW in the states is less than half the price.

    Cush drive and sprocket holder needs new bearings
    [​IMG]
    The cush drive rubbers are also stuffed. They are split
    [​IMG]
    The bearings are easy enough, I've done that job before.
    There is a guy in RSA that makes replacement cush rubbers. They fill the space much better so there is less movement of the rubber in the cavity. And so less wear. ±$150 for aftermarket and $225 for OEM. Easy choice

    The chain roller and swing arm guard need replacing
    [​IMG]
    [​IMG]
    [​IMG]

    The bottom neck bearing will need replacing the top one is still 100%
    [​IMG]
    But the nut on the neck was VERY loose. Just about loosened it by hand. Not good

    There is a BMW power socket that has been wired into the loom.
    [​IMG]
    I have also installed one of these before and I know this is not standard as the kit comes with a male and female plug as well as a fuse. All just plugs in and no cutting. None of that here. I will have to find out what has bee removed from the loom.
    #10
  11. rc mad

    rc mad Physycotic gecko

    Joined:
    May 9, 2006
    Oddometer:
    1,559
    Location:
    Deeping About
    On some (most?) bikes that power socket is standard fitment, my 06 (with abs and heated grips) has one. I would not be tearing into the loom to remove it! Check with bmw first, they should be able to tell you if it was part of the bike build or not.

    Not had my 06 that far apart, yet, I'm getting the urge to rip the abs system off the bike though :lol3

    Its the sv650's turn first :deal
    #11
  12. Aquatic

    Aquatic Long timer

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    Oddometer:
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    Location:
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    Definately not a OEM/standard installation!
    #12
  13. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
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    Location:
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    Progress is slow at the moment as I have contracting that is taking up my time. But hopefully the pay day will be big and beneficial to the project.

    In the mean time I've come up with and engine stand design to get the donk off the floor and moveable.
    I will be adding casters with brakes. To lazy to add them into the design right now.

    [​IMG]

    I also added extra holes so the engine can be rotated side to side if needed

    [​IMG]

    The bosses are away tomorrow and Tuesday. So I should have something to show before the end of the week.

    I also received a package from Tmotten.:evil Got some parts to design! Watch this space
    #13
  14. AtlasExp

    AtlasExp beer me

    Joined:
    Nov 29, 2010
    Oddometer:
    463
    Location:
    Brooklyn, NY
    Maybe in mean while you can post more pics what you all ready did? For engine stand I use car engine stand with couple extra brakets!!! Subscribed an waiting for more!!!! :lobby
    #14
  15. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    I don't expect it back in a hurry considering the time of year. But that actually suits me at this moment in time.

    All holes are plugged. I just need to straighten the the 2 tabs on the lower frame that hold the bash plate on. And the brake pedal needs straightening.
    Also need to make plugs for the neck.

    [​IMG]
    #15
  16. divimon2000

    divimon2000 Been here awhile

    Joined:
    Apr 16, 2011
    Oddometer:
    637
    Location:
    Lake Champlain, Vermont
    One more vote for std equipment accessory harness. Mine's exactly the same.
    #16
  17. ben2go

    ben2go Moto Flunky

    Joined:
    Jun 23, 2011
    Oddometer:
    4,621
    Location:
    Upstate SC USA
    The more 650gs builds I see,the more I want one.I look forward to this build.

    I use a bench mount VW engine stand for my bike engines.It's the head of an auto engine stand with a bracket that bolts to the bench with adjustable arms.However,my Suzuki GS engines are easier to work on just sitting on the bench.:thumb
    #17
  18. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    (edit: 'scuse my spelling in the heading)

    From this.....

    [​IMG]


    To this......

    [​IMG]
    [​IMG]
    And the pillar folds down for ease of storage.

    Possibly an over kill as it won't be used that often. But I had the materials, time and machinery to make it, so what the hell, I did!:evil


    And the powder coating parts should get back tomorrow, woo hoo.:clap

    I have a set of fat bars on the way that were lying collecting dust in a fellow inmates shed. Thanks DrJohnno.:clap

    Just need to confirm some cash income and I will be placing and order with MaxBMW USA for some spares. (Including shipping still way cheaper than here in Aus):deal

    I have a set of KOYO sealed neck bearings lying in the back of an AusPost van on its way to me.:clap
    The triple clamps design is "in work":clap

    So things should start picking speed in the next couple of weeks. After New Years of course:freaky
    #18
  19. Loutre

    Loutre Cosmopolitan Adv

    Joined:
    Nov 28, 2010
    Oddometer:
    9,001
    Location:
    :o)
    miam miam miam! I'm all yours! build this pig together and get some sparkles in my eyes :D
    #19
  20. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    My order with MAX Bmw in the USA is placed and paid for. Drew, the saleman, has been very efficient and helpful.
    Christmas comes late in the Krantz household.:clap:clap


    The powder coating is back and looks 'tit'!:D
    The guys did an absolute awesome job!
    I will post pics once I have completed all the clean up(threads, burrs, etc)


    The new neck bearings have arrived.
    [​IMG]
    $63.14 for 2
    Possibly no the cheapest, but they are sealed!!!
    They are not in the online catalogue. So I phoned and the guy knew exactly what I was talking about and told me which supplier in Brisbane to phone to get them. 12 in stock - I'll have 2 please :evil. Auspost wasn't as effiecient over Christmas. 'tis the season so they can be forgiven.


    The exhaust is at work at the moment. I tried pickling paste in an attemt to clean up all the stains and get it nice a nd shiny. Not a chance!!! Didn't even make a difference.
    I will have to put the scotch brite wheel to work. A bit of elbow grease with dollop of sweat!


    I also took some degreaser to the engine today. Looks like I will have to soda blast it. Ingrained stains!


    The handle bars are in the garage and the triple clamps design is taking a little time as I have been busy assembling my radio mounts(see my signature below) for paying customers. Still got to pay for all the swingarm bearings!!:D



    Things might go quiet for the next 2 weeks as I have a bit of contract drafting that will keep me busy in the evenings, as well as the Dakar to follow.
    #20