BergDonk's DR650s

Discussion in 'Thumpers' started by BergDonk, Dec 20, 2010.

  1. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    Hi Bushy,

    Thanks for the support, good to hear from you. The deals on ebay were too good to pass on, and the results have been justified. Its a wonderful, go anywhere, tourer.

    You've been quiet over on UHE of late, Taffy get to you?

    Maybe catch up when I head over with Azza, assuming I'm back from the Kimberly before he heads off?

    Steve
    #81
  2. Bushmechanic

    Bushmechanic Adventurer

    Joined:
    Apr 1, 2010
    Oddometer:
    74
    Looks like Ive been missing some really great deals on ebay, will have to check it more often.

    Re the swingarm cracking being re welded and and then re cracking, has anyone put a patch over the reweld ? if its a vertical weld in a problem area it prolly should have a patch with a horizontal bead top and bottom ?

    Yes took me a while to concede but Ol Taff is just too tedious to communicate with for my liking :huh the online stuff is full of only mild misunderstandings, by comparison there are 192 emails in my inbox from him :eek1 .

    Not sure when Azza rides out, but yes be great to catch up, there are a few local spots I haven't been for a while be glad to show you around if you have time. Goes without saying of course that you can use my shed FWIW to fix up stuff if you need to.
    #82
  3. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    I was looking for a while for some forks, Snowy and LukasM, and rocks around here, and my Bergs suspension got me thinking that more than what I had woul be worth the effort. No fixed agenda, just a cartridge fork that wouldn't be too hard to fit. The WP CCs turned up and after explaining to my wife the benefits, I had her approval to bid. You have to have a want, then patiently keep looking, and eventually it turns up. My 3 mates over here with DRs have asked me to keep an eye out for an Ohlins for them after testing mine, and one is about to fit some DRZ250 forks that were at a wrecker in Canberra at a fair price. He doesn't want to change the ride height, or travel too much, and will have to get them modified to suit with springs and valving, and will end up more expensive than my WPs which have, for me, perfect valving and springing stock.

    A mate of Frank's in Sydney specialises in alloy frame repairs and modifications so that is where my swingarm will end up. Plating the suspect weld certainly seems like a way forward. Looking at the weld, I assume its a tensile failure mechanism. I want it fixed, before it fails.

    Taffy is a special case, no doubt. I did catch up with him last time I was over in Blighty. It was a good night, but he does have issues. Maybe I'll come home from the Kimberly via the Canning and catch up then. Shed offer appreciated, and keen to see the new frame in action too.

    Did 400 kms yesterday and was mainly thinking about the FCR. One other bike along was an almost stock DR650, the one about to get the 250 forks. We had a plan to get to the coast, and that would have been interesting to check how much leaner I can go, but we ended up staying up high. Another day... FWIW, the FCR is better, more snap, and reponsiveness, but if all you do do is cruise, then there is no value over and above a properly setup stock BST40. The more technical the terrain and riding, the more the FCR's benefits are appreciated. Fuel consumption so far seems about the same, but I need to do some more kms to confirm. I started with a full tank, and after 393 kms still have 200+ kms in the tank.

    Likewise with the suspension, as terrain gets more complex, the benefits are realised. If you don't go anywhere but dirt roads and easy fire trails, there is no point to a conversion, although I'd always recommend the proper springs for your weight. And on the DR650 that invariably means heavier springs, and then the damping is overpowered. So if you can do stuff yourself, the cost of a conversion is not that much different to an upgrade of the stock components, which will never be as good, but then are nevertheless good enough for most.

    As Dale Lineaweaver once said, the best you've ridden, is the best you know.

    Steve
    #83
  4. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    Time to finish my racks. I got some Wolfman pannier bags last year and have been trying to make time to make some racks to suit. I used some 8mm bar for the outer frame and and 6mm bar for the 2 vertical risers. Some 25 x 3 and 25 x 4 flat for the attachments and should be OK.

    I printed out a picture of the Wolfman frames off the web and scaled the dimensions from it. I didn't buy the genuine item because I wanted them a bit lower and further forward, and gotta justify the MIG. Cost about $10 + a day in the shed. I also changed the strap that goes over the seat so I don't have to sit on the buckle.

    Will test this weekend as am off to the Wallerwang and the Hunter Valley.

    [​IMG]

    [​IMG]
    #84
  5. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
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    Ready for loading.

    [​IMG]

    The tank pannier bags I got at the same time from Procycle too. After some playing about with webbing they work well, and have done a couple of trips to date, including 900 kms to Dargo and back via Pinnibar and Billy Goat Bluff last year.

    The Gearsack is an old one that still provides great service. It was purchased new in about 1982 and has been on my then GPZ1100, ZX10, and ZX9R. Probably done 200,000 kms and only replaced the zip once. pity they don't make them anymore.

    As previously mentioned, the rack is a Ventura one i had that I cut up to fit and dispensed with the 'roll bar'. They can hurt in awkard situations!

    To keep some shape and attach it I raided the kitchen for a nylon cutting board and had some aluminium flat in the shed and some webbing strap. Works well, and gotta see if I can wear it out. The pic below shows the inside.

    [​IMG]

    Still enough room for a dry duffel on the pillion seat.

    Steve
    #85
  6. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    And I got these LED driving lights on ebay. Bolted on to my blinker mounts with no mods. they are 1500 lumens and draw 10 watts each so just piggy backed them onto the high beam circuit which I previously upgraded with a Philips + 80% bulb and wired direct to the battery via a relay.

    [​IMG]

    http://cgi.ebay.com.au/ws/eBayISAPI.dll?ViewItem&item=120678251855
    #86
  7. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    I got a second hand swingarm from the wrecker which is currently in Sydney with a specialist frame builder ally welder being beefed up. I plan to collect it on Monday.

    Almost ready for the big one in June and July.

    What have I missed?

    And I forget to mention that once my racks are tested, I will pull it all apart, tidy up my welds and get it all nickel plated.

    Steve
    #87
  8. rowdy_im

    rowdy_im KTM 625 Snowy Mountains

    Joined:
    Apr 21, 2007
    Oddometer:
    382
    Location:
    Jindabyne Australia

    Wheres the photo,s Mr BergDonk
    I can,t be seen hanging around in DR pages for too long ,,,the KTM brothers may think I have defected

    Rowdy:evil
    #88
  9. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
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    Oddometer:
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    Location:
    Snowy Mountains Oz
    Lust, you have a 625 and now lust for a DR650? Which pics did you have in mind?

    Just realised the lights are 30 w each, so will fit a relay. No biggie.

    And the long range fuel tank arrived for the ute today, water tanks to come. This is proving to be an expensive trip. Must be your fault, it was your idea...

    Steve
    #89
  10. a1fa

    a1fa Throttle Jockey™

    Joined:
    Nov 1, 2006
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    14,788
    Location:
    Arkansas
    She is all ready for a long range adventure. You go man!
    #90
  11. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    And where are the pics of your new fuel tank?
    #91
  12. rowdy_im

    rowdy_im KTM 625 Snowy Mountains

    Joined:
    Apr 21, 2007
    Oddometer:
    382
    Location:
    Jindabyne Australia
    look on my smug mug album

    Rowdy:1drink
    #92
  13. AdventureXR650

    AdventureXR650 Esquire

    Joined:
    Sep 1, 2007
    Oddometer:
    147
    Location:
    Yass NSW Oz-trail-ya
    Bergdork those light look lovely and how'd you come about them??:huh

    I bloody hope there are still some left when I get paid. Sent my stator and left switch block away to Betta Bikes to get an a electrical upgrade to cater for the 30w each light draws. Should be way better than these
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    #93
  14. rowdy_im

    rowdy_im KTM 625 Snowy Mountains

    Joined:
    Apr 21, 2007
    Oddometer:
    382
    Location:
    Jindabyne Australia
    Ordered mine tonight,will look at fitting them next week,
    I was going to fit a inline switch and use the cig plug on my dash to plug them into,whats the worst that could happen:muutt:kboom
    hope they last the distance ,or will have to write some strong words to the individual that recommended them:evil:evil

    Rowdy
    #94
  15. AdventureXR650

    AdventureXR650 Esquire

    Joined:
    Sep 1, 2007
    Oddometer:
    147
    Location:
    Yass NSW Oz-trail-ya
    Sourced a local motorcycle engine builder ex Honda team with a Dyno. Got max dollar which it won't be as probably just a set of rings and a tune.

    Brought lights today and things are starting to come together. If only I had F.A. to do like Bergdonk here and a shed and tools and space.......heard it all before from me ay mate.....lol

    When's next meeting?:freaky Been styling in that hat? :rilla
    Why is Kowen in the weekend of my mothers 70th? You think she'd mind if I went riding instead of celebrating with her and ALL my family? Yeah me too. :cry

    telle est la vie
    AXR
    #95
  16. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    My daughter Martina scored the hat, wears it late at night clubbing in Civic now.

    Next meeting, you must be hanging for another go on Sandra's KLX?

    Lights are good, but I just may not be able to have them on and the grips, we shall see.

    I get to ride Kowen all week, arrowing, then sweep ride the weekend. You should retire too, then you could too.

    Steve
    #96
  17. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    Trying to keep it a bit simpler than Snowy, maybe, and I don't want a broken bit in the Kimberly or Simpson later this year, so some 5 mm and 3 mm plate, and someone who knows 6061 ally and TIG, and voila:

    [​IMG]

    [​IMG]

    The bearings were removed, and the plates were fitted over the existing welds. The arm was held in a jig while it was done. No material was removed. Notice how little heat was used, the only clear coat removed was done mechanically, none burnt.

    Steve
    #97
  18. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
  19. nolana

    nolana what's that skip?

    Joined:
    Jul 22, 2007
    Oddometer:
    8
    Location:
    Snowy Mountains NSW
    very tidy bit of work steve. always pays to find good help. can't be much left to do now!

    adjusted the valves on the berg yesterday after that first hour or so of riding - bit tight all round, but not too bad. just need to find time for a squirt now...
    #99
  20. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    5,347
    Location:
    Snowy Mountains Oz
    After for some 1000s of kms now, the racks and misc brackets I have made are all off being zinc plated at the moment.

    New chain and sprockets from Chaingang, and new wheel bearings, are in the shed to be fitted just before the off. I still want to make some more carrying capacity on top of the passenger pegs, which I'm keeping operational.

    Almost ready to go though.

    When are we riding?

    I tested the driving lights, they are very good, surprising in fact. The charging system handles the extra 60 w and high beam fine, and the grips on low too. With the grips on high, the voltage jobs 0.2 v, from 14.0 to 13.8, so probably just OK too, but we shall see.

    Steve