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

    To find out what to look for - http://advrider.com/forums/showthread.php?t=441434
    It's a very long read, but you won't be sorry.

    Sign up to Wild Dogs and look here - http://www.wilddog.za.net/forum/index.php?board=92.0

    And lastly - http://f650.com/forum/forum.php


    What changes did I make? That is an on going thing as with many Dakakr owners.
    The only major change on my bike at the moment is the Yamaha fork replacement(I bought the bike like this)

    Nah mate, no decent biltong here. You have to go looking for it at the Expat shops. There is a South African butcher in Brisbane that makes decent biltong.
    #61
  2. Joe Soap

    Joe Soap n00b

    Joined:
    May 15, 2012
    Oddometer:
    3
    Location:
    Sydney

    Hi Mate<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
    Immigrated to Australia "Sydney" 4 years back from South Africa, I have just discovered that the frame on my F650GS Dakar 2007 is bent after I dropped the bike.<o:p></o:p>
    After discussing the matter with my other half, I decided to break down replace the frame and rebuild the machine.<o:p></o:p>
    If you have any advice on the matter, I would greatly appreciated it.

    Cheer's <o:p></o:p>
    <o:p></o:p>

    <o:p> </o:p>
    #62
  3. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    All depends on what your overall plan is, available time and budget! Do yourself a favour and actually write up a plan of what you want to do. Work out a priority list and start there.
    Lack of funds is why my project is at a standstill at the moment. But I also have a lot I have planned to get done. A lot I can do, but there is still stuff I need to pay to get done.
    I also found out the Mrs is "up the duff" so I will most probably have to trim my list down to get it done before the end of the year when all hell is gonna break loose and all spare funds will be allocated to nappies and formula!:D

    How old is your motor? Even though they are bullet proof, check waterpump, clutch and valve clearances.

    Look at a fork conversion - this depends on your riding style and needs. But you won't be sorry.
    Rear suspension will need an upgrade if you do the front (my opinion)

    I'm replacing ALL the bearings and seals on the bike(excluding the engine. That is planned for later)
    Especially on the swingarm.

    I'm modifying the oil lines and possibly adding a cooler.

    Battery upgrade.

    Some people swap out the dash. That isn't in my plans.

    If you ride at night, the lighting needs work.

    If you have any questions, just ask. But be aware, I have no experience and I'm winging it:evil. I do happen to be handy with tools growing up in my dad's garage and being a fitter and turner.
    A copy of the workshop manual will also serve you well!

    Good luck and post pictures
    #63
  4. Gravel Seeker

    Gravel Seeker Thomas

    Joined:
    Apr 27, 2002
    Oddometer:
    4,961
    Location:
    Dreary old Norway, dreaming of adventures past
    :freaky
    #64
  5. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    Ta.
    Even though it is riding time and budget gone, it is good news:clap

    #65
  6. Joe Soap

    Joe Soap n00b

    Joined:
    May 15, 2012
    Oddometer:
    3
    Location:
    Sydney
    Aquatic, thanks for your input and advice on the matter mate, the last time a broke down and rebuild a bike was in the 80’s when I did my 84’ TT 600 Yamaha, which does not come close to the 2007 Dakar.
    Spent a few hours in the garage over the weekend breaking down the bike taken quite a bit off, basically down to the abs, engine and wiring harness.
    Quite a few smaller items require replacing and the rear shock which is shot. I will upgrade the front forks at a later stage as they are easy item to work on and get to. At this point in time concentrating on the frame, engine, upgrading the rear shock and small items that require immediate attention. I replace all the bearing and seals in the swing arm May last year.
    All I know the bike needs a good spit and polish and lots of elbow grease.
    Cheer’s
    #66
  7. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    So I finally managed to spend time on my bike. Hopefully this carries on for the foreseeable future


    I have read a lot about what needs to be done to keep the swingarm bearings in good condition. Regular strip and regrease. Especially after some water crossings.
    So I decided to try something.

    I got extra 4 seals used on the shock linkage - pn 33 53 7 650 097 - Seal G22X28X4

    So I stripped out the felt washers and the inner bush
    [​IMG]
    [​IMG]

    Using the studs, special washers and studs I made up previously I shifted the bearings inwards another 4mm
    [​IMG]

    I inserted the new seals. And with the bearings shifted inwards there is still space for the felt washers
    [​IMG]

    So in theory, I have a water tight seal and dust protection with the felt washers. The cavity is also FULL of grease.
    All assembled
    [​IMG]

    And sealed ready for assembly in the future
    [​IMG]
    #67
  8. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    Another problem I noticed when I stripped out all the bearings from the wheel hubs. My sprocket carrier has been attacked by a rabid Bull Mastiff!
    Some one before me didn't have tools or an idea!:baldy
    [​IMG]

    I get the impression the bike was ridden with a collapsed bearing and the chain has also climbed off the sprocket
    [​IMG]
    #68
  9. Spyker

    Spyker Been here awhile

    Joined:
    Dec 22, 2003
    Oddometer:
    203
    Location:
    Planet Earth
    Any update? Is it running yet?






    PS. Hou op rond tos en bou die ding!
    #69
  10. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    No, not running yet :cry

    But.........I been doing a little work here and there

    Then,

    [​IMG]
    [​IMG]

    and Now,

    [​IMG]
    [​IMG]
    [​IMG]

    Hubs - Black powder coat
    Spokes - Blood, sweat and Autosol (fuck me that was hard work)
    Nipples - unfortunately new are beyond budget. So I just sprayed them with Galv spray. Not what I wanted, but hey!
    Hoops - powder coated the inner face and left the edges masked. Afterwards polished the edge to (almost) mirror finish.

    Back wheel next and then I will send them for professional trueing.
    #70
  11. Gravel Seeker

    Gravel Seeker Thomas

    Joined:
    Apr 27, 2002
    Oddometer:
    4,961
    Location:
    Dreary old Norway, dreaming of adventures past
    Nice !
    #71
  12. kubiak

    kubiak Long timer

    Joined:
    Nov 25, 2007
    Oddometer:
    4,837
    Location:
    madera california
    nice work!
    #72
  13. LoJack

    LoJack Long timer

    Joined:
    Apr 4, 2008
    Oddometer:
    1,622
    Location:
    B.G., yo!
    Great idea to mask the edges of the rims. The powder coat would just get messed up from spooning the tires on and off.

    Looks great!
    #73
  14. FabOneUp

    FabOneUp Been here awhile

    Joined:
    Jan 23, 2007
    Oddometer:
    144
    Location:
    9200 ft. USA
    :lurk
    #74
  15. nomad5326

    nomad5326 Xventurous

    Joined:
    Feb 10, 2012
    Oddometer:
    309
    Location:
    San Diego, Ca
    I wish I had your talent, skill and patience! Beautiful work and looking fwd to your next piece of work!
    #75
  16. kubiak

    kubiak Long timer

    Joined:
    Nov 25, 2007
    Oddometer:
    4,837
    Location:
    madera california
    looking great!
    #76
  17. Spyker

    Spyker Been here awhile

    Joined:
    Dec 22, 2003
    Oddometer:
    203
    Location:
    Planet Earth
    Any update? :D
    #77
  18. JonnyC

    JonnyC I take photos

    Joined:
    Jul 16, 2013
    Oddometer:
    59
    Location:
    Land O' Lakes WI
    ANY UPDATES!! This was a sweet thread. Are there any conclusions?>???? :norton
    #78
  19. Aquatic

    Aquatic Long timer

    Joined:
    Dec 23, 2008
    Oddometer:
    2,154
    Location:
    Buddina, Sunny Coast, Australia
    Hey I'm back :clap:clap:clap

    Just got to dust everything off. 'cough'
    Guess what happens when you make plans to finish a bike rebuild. Life and other stuff! :cry

    Anyway I should be adding to this thread a lot more regularly from now on.

    I have a bike lift that doesn't quite suit my needs
    [​IMG]

    So I got an idea and built another lifting platform
    [​IMG][​IMG]

    So now the bike is loaded, jacked up higher and there is clearance below the bike
    [​IMG]


    I also made a front end jig
    [​IMG]

    To do the necessary modifications to a YZ front end I picked up off of Gumtree. I had to sell my original front end to get some funds. Hopefully this set will stay mine. But who knows? Things happen. I might get an offer I cannot refuse
    [​IMG]

    The mod parts have started
    Calliper mount
    [​IMG]

    ABS Sensor Mount,Hooter bracket and Front Fender support are on the way.
    Axle shaft and spacers also "in work"

    Watch this space :freaky
    #79
  20. Gravel Seeker

    Gravel Seeker Thomas

    Joined:
    Apr 27, 2002
    Oddometer:
    4,961
    Location:
    Dreary old Norway, dreaming of adventures past
    Sweet setup :clap ......envious... :cry
    #80