DR 650 project: It's now a Beast!

Discussion in 'Some Assembly Required' started by DRjoe, Feb 4, 2009.

  1. NordieBoy

    NordieBoy Armature speller

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    If you undo the front bottom(ish) case bolt it comes out a lot more easily.
    They go in more easily that they come out too.

    Now that's a worn set of gears.
    #41
  2. DRjoe

    DRjoe Long timer

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    Sorry for the lack of posts guys.

    I finished the motor and i was very disapointing with how much power it was kicking out so i was put off the project for a while.

    I rode the bike around for a while wondering why it was lacking power when all other reports say that the hi-comp piston makes a big difference.
    After seeing a picture of a je hi comp piston I have come to the conclusion that the piston I got from the bike shop is not a lot different from the stock (the je is flat on top and my piston has a concave like the original).

    any way whilst i was thinking about the next plan of attack the head gasket started leaking this has given me the excuse i need to get the head skimmed and raise the compression to about 10.5 to 1.

    here's a few questions for you very helpful people.

    does anyone know if i will have to change my ignition timing to suit and if so by how much?

    is there a programmable icu available for the dr?

    is it possible to skim a head on a lathe or do you need a mill?

    and why is the sky blue?

    hope there are still people watching this thread as your input is very welcome.

    cheers

    Joe
    #42
  3. DRjoe

    DRjoe Long timer

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    I have thought of another question.

    Would a tuned air box make a difference to the dr?
    #43
  4. Kawidad

    Kawidad Long timer

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    In my limited knowledge, 10.5-1 should just fine with no other modification needed. You can get into the 11+ to 1 range before you have to worry about ignition timing and pinging.

    As far as how to do it. A mill is the best way. It must be very precisely done, or else you're looking for trouble. :thumb
    #44
  5. Mezo

    Mezo Banned

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    The blue color of the sky is due to Rayleigh scattering. As light moves through the atmosphere, most of the longer wavelengths pass straight through. Little of the red, orange and yellow light is affected by the air. :D

    Of course were all still here, we just been waiting for you to come back :lurk


    No you cant skim a head in a lathe (not that one anyhow) gotta be done on a mill, John Boston is doing my head as we speak, porting, re-angle valve, skim etc. have a look here joe

    Im about to do a build myself http://lightwire.net.au/mezo-dr650-rebuild.html

    Mezo. :thumb
    #45
  6. DRjoe

    DRjoe Long timer

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    Ok so i have finaly got motivated and started on the dr again.

    I have bought a programmable cdi from these guys http://www.ignitech.cz/english/aindex.htm
    [​IMG]

    I have ordered a set of black plastics for a drz400e you never know they might fit.

    A fellow inmate put me on to these lights from hella so I have ordered one for low beam and i have some projector lights that I'll use for high beam.
    [​IMG][​IMG]

    I have started on the rally style light mount/ nav tower thingy.
    Here are a few pics of the first stages with my newely aquired touratech road book.
    [​IMG]
    [​IMG]


    I decided against welding a lug to the steering stem so i made a bracket that bolts on.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    The bottom light thats in the pic is just there to show me what it will look like i'll eventualy instal the hella there.
    Should i go with two top lights
    [​IMG]

    Or one
    [​IMG]

    New handle bars, the local bike shop say there un-bendable
    [​IMG]

    sorry about the small photos.

    What do you all think?
    #46
  7. Mezo

    Mezo Banned

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    Excellent Joe :clap

    Haa, programable cdi, i was talking to Sander the other week about the same thing.

    Lukas will love this, you going to make a fairing to cover the lights yeah ?

    :lurk

    Mezo. :thumb
    #47
  8. DisTech

    DisTech Been here awhile

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    Beautiful work Joe! How are you cutting your brackets? You have a laser or water jet cutting table? Looks like you have metal forming equipment and skills as well.

    Does the bracket passing between the forks interfere with turning radius?

    I like the look of two top lights, but not sure what that would do to the final fairing. How much gear are you going to run besides those lights? Will you have enough juice?

    I'm on board! :lurk
    #48
  9. DRjoe

    DRjoe Long timer

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    There will be a fairing, i dont know if i'm going to make it from scratch or convert a bought one.

    I'm cutting the brackets with a very cheap jig saw and finishing them with a file and a sander.
    I'm bending the brackets buy hand in a vice.
    Its not that hard.

    I'll use HID for low beam and halogen for high beam so it should only total about 115w to 145w depending on what lights are use for what beam.
    I'll run heated

    The original cdi is powered buy a seperate alternator, the new one just runs off the battery I'm not sure how much power the cdi will use.
    It does mean i can put a regulator on the spare power out put that comes from the alternator.
    In other words i can have two charging systems and maybe even two baterys.


    What should i make the fairing out of plastic or glass fiber?
    If i go glass fiber i'll make a composite using alloy sheet to make the shape and then sandwich that in fiber glass.


    thanks for the input guys.

    Joe
    #49
  10. Mezo

    Mezo Banned

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    Haaa, be like close encounters comming down the highway :evil

    [​IMG]

    :lurk

    Mezo. :thumb
    #50
  11. NOSIGN

    NOSIGN Adventurer

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    thats gonna be awesome. I think i'd use two lights not three, but im interested either way. Nice work so far!
    #51
  12. Mezo

    Mezo Banned

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    Hey Joe ive been reading other forums on that clever bit of kit, shift light, rev limiter, quick shifter, tacho, kill switch, program button (allows you to press a button & change the ignition timing for a given time set by you) handy in the wet. You can set the ignition at 15 points through the rev range, i think ? if its the same as other ones for other bikes.

    And you could use this a a nifty security device (if yer smart) :evil

    Looks pretty simple to hook up.

    [​IMG]

    :lurk

    Mezo.
    #52
  13. dylandr

    dylandr Been here awhile

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    Got the 2008 DR 650 and just did some mods to give it that ralley look too. but I wasn't keen to strip the stock stuff off the front of my baby... So I left it on and built around it. Wish I had the guts to just rip the front end off! Looks good though... show me more:lurk
    #53
  14. Mezo

    Mezo Banned

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    Well lets see yours then :lurk

    And fill out your profile :deal

    Mezo. :thumb
    #54
  15. dylandr

    dylandr Been here awhile

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    :amazon Gonna have to hold on a while... only large pics available!:amazon
    #55
  16. dylandr

    dylandr Been here awhile

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    Will take som more tonight... Gotta get the size right cause this forum doesn't take a huge format Jpeg
    #56
  17. pookiebear

    pookiebear Long timer

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    This thread needs WAY more pics.
    tuning in for sure.
    #57
  18. DRjoe

    DRjoe Long timer

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    the cdi came with a wiring loom for the dr and it came with a disk that has what they think your timing should be set at.

    Its just plug and play.

    You can get the cheaper one for a standard dr that will do 2D maps but i wanted to use the tps sensor that's on the pumper carb so i can have 3D maps.

    It has several outputs for shift lights, solenoid's and servo's and also it has two inputs that you can choose what they do i'll have one set to retard the ignition so that i can run on crap fuel and the other will be an engine cut out connected to the clutch, this cuts the engine for a preset time when the clutch is pulled so that you can change gear whilst still on the throttle.
    (that's mainly to protect the gear box from my lack of riding skills)



    I'll try and get some more work done tonight and then i can post some more pictures to keep you all happy
    #58
  19. dylandr

    dylandr Been here awhile

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    :baldy Having problems uploading pics... any advice?
    #59
  20. LukasM

    LukasM Long timer

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    Photobucket.com Free, easy, quick
    #60