DR 650 project: It's now a Beast!

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

  1. sailah

    sailah Lampin' it

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    Joe,

    I have done 2 PDS swingarm conversions in my builds and they both work great for the reasons you mentioned. Simple, easy to install, components are readily available and since they are offered in much heavier bikes, it's easy to get springs from 690/950 bikes that will work on your project.

    For the FZ1 where I ran a 950 swinger and shock, I was constrained by the airbox, leaving my with a shock just slightly canted forward. I scrapped the airbox and went to pod filters and that allowed me to get the angle that looked "right". I then removed the spring from the shock, lost the nitrogen charge and cycled the swingarm to make sure that the swingarm with wheel went through the full stroke and that the shock also did the same. That ratio helped me place the shock in the right place and I welded it down. I left it tacked in while I was running tests and communicating with my tuner.

    His advice was to get the rake you want with the front end first. Easy, I duplicated a 950 SE geometry. So I installed the front end completely with wheel and used a floor jack to lift the rear of the bike until my magnetic angle gauge on the forks read 27 degrees or whatever the angle was I forget. I then build my scaffolding for the rear shock mount, tacked it in and dropped the bike on its weight. Invariably something would be off slightly, so it was back up in the air etc.

    One of the guesses I got very close to my geometry angles. Now the rear of that bike the swingarm pivot is higher than the 950 so I was heading into uncharted territory. At some point, you have to be happy with good enough. I'm not some A level rider and I don't want to bang my head on the wall that it was off by half a degree etc, I just wanted to ride.

    So anyways after all that, I rolled the bike out of the garage for its maiden voyage and have done 7000 miles since then and the bike has worked great. everyone who has ridden it never comments on that half a degree. Honestly for much of that build, and the one I'm building now, I rely on my eyes, hands and common sense. That might now be good enough for MotoGP, but my goal is to actually finish my projects and get a rider. Too many builds stall out because people either get mired down in the minutiae or lose focus.

    I think your plan for a new frame is excellent as well as the PDS shock setup. Hands down the easiest to get right. A linkage might be better, but its a 650 heavy bastard to begin with right??:lol3

    I have a few KTM PDS shocks from an 03 to 08's if you can't find something locally for a reasonable amount.
  2. DRjoe

    DRjoe Long timer

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    Have you got a 950 shock or have you worked out away to use a standard PDS shock with a 950 swing arm.

    I have a computer program that let's you change shock and swing arm orientation virtually, it's been a great tool for learning.
    I was surprised how much difference it made to the progressiveness of the suspension when you change the shock angle slightly and also how squat can be changed from + to - just within a few degrees of movement withe the swing arm.

    But saying that I did exactly the same as you just recently when I was messing with my new dr650 that has drz suspension.
    I copied the drz rake and swing arm angle and just adjusted it buy taking the dog bones out and jacking up the rear until the forks where at the corect angle then I made some new shorter dog bones.

    The difference in the bike is amazing much less squat than before and turns much better.
  3. sailah

    sailah Lampin' it

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    I have a 950 shock on the fz1. The cbr has a exc swingarm and regular pds shock.
  4. WILL_S

    WILL_S OUTLAW POSTIE 001

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    boredom+grinder=dr subframe removal
    pics:ear
  5. DRjoe

    DRjoe Long timer

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    Back to my old ways

    [​IMG][/IMG]
  6. NordieBoy

    NordieBoy Armature speller

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    What if you get bored of stoppies?
  7. thumbs up we're off

    thumbs up we're off Adventurer

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    I realise you've probably finished your project, but for those DR addicts seeking Head mods check out http://www.procycle.us/bikepages/dr650.html their DR products are sensational.:D
  8. b0mb3r

    b0mb3r Old Git

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    do u have any bikes in one bloody piece Joe ..... poor old DR :cry
  9. DRjoe

    DRjoe Long timer

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    You've got a point nordie maybe I should put a wheel on the back.

    The Postie is on one piece (almost) Martin.

    Tell ya what doing this second time round is a fair bit easier and quicker.
    Top mounts are done and I should have the bottom ones done by tomorrow.
  10. ThumperStorm

    ThumperStorm Long timer

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    So, what is happening? Is this thread dead?:hmmmmm
  11. DRjoe

    DRjoe Long timer

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    Nope just having a nap
  12. Thunderhart8

    Thunderhart8 Been here awhile

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    Its a non stop great project love the build. I have need reading for 2 hours. I am thinking of taking on something similar. Subscribed !!
  13. DRjoe

    DRjoe Long timer

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    One day it will continue.

    I'm starting to get an itchy grinder trigger finger.
  14. kellymac530

    kellymac530 motorcycle addict

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    So you started off saying this DR650 was going to be a KTM killer....keep throwing enough KTM parts at it and MAYBE it will be....just forks, frame and motor to go.

    Im just saying.

    Seems like you like working on bikes more than RIDING bikes at this point. I have not had to redesign a single thing that took more than a few hours to rework on any of my 3 KTMs over the last 12 years. I swapped the crappy smog vacum slide carb on my Lc4 400 to a FCR, 2 hours. I made a custom water catch bottle out of a baby bottle for my 530 and some rear foot pegs for both just in case...other than that I just ride them.
  15. DRjoe

    DRjoe Long timer

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    Good onya mate your a legend



  16. WILL_S

    WILL_S OUTLAW POSTIE 001

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    Need to go for a ride mate
    one of all those bikes must be going
    braaaaaaap
  17. NordieBoy

    NordieBoy Armature speller

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    You smooth talker you :rofl
  18. NordieBoy

    NordieBoy Armature speller

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    Some people get a buzz from making/remaking things for their bikes.

    Some are just legends :evil
  19. LukasM

    LukasM Long timer

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    :rofl


    Looking forward to seeing you apply those new skills to make a decent bike that won't blow up out of that Suzu... kati this time Joe. :freaky
  20. DRjoe

    DRjoe Long timer

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    Yep, Where are we going?