DR350 supermoto project on a KLR budget

Discussion in 'Some Assembly Required' started by dbarale, Nov 16, 2011.

  1. rangtangtang

    rangtangtang Been here awhile

    Joined:
    Jul 27, 2011
    Oddometer:
    192
    Location:
    Uganda, East Africa
    Still got loads to do, and its happening extremely slowly.
    In good time.
  2. 99Bandit

    99Bandit Been here awhile

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    Aug 18, 2011
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    SE Wisconsin
    You did a fantastic job on this build. Do you mind saying what the total cost ended up being?

    Seeing your bike really makes me want to do one of these too. :deal
  3. dbarale

    dbarale Squiddly slow

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    Thanks. I bartered my time for the bike and most parts, so my "out-of-pocket" cost is only about $100. But here's what someone else might expect to pay.

    Bike: $700
    Tires: $220
    Piston, valves, gasket set: $300
    Wheels: $150 (less if you're lucky/patient)
    Random paint/oil/filter/etc: $100
    Machining: $100

    Total: $1570

    Of course that's assuming you do all the work yourself. If you already have the bike and just want to do the conversion there are other options. B.curvin was selling recently a set of supermoto wheels and tires ready to bolt on for $500 or $600. Well worth it.

    Another option is to trade your 18" rear wheel for a 17" from a DR650. Get a set of spokes from Buchanan and lace that 17" rim on the front hub, get a wider 17" from Ebay and lace it on the rear. You now have a set of spoked supermoto wheels for less than $200. But the brakes would still be stock, you'd be running tubes and lose the option of switching back to dirt wheels...

    Did I mention I like the look of the GS wheels anyways? :evil
  4. 99Bandit

    99Bandit Been here awhile

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    SE Wisconsin
    Not bad for $100 bucks out of pocket! :clap

    It does pay to have friends in the right places. :evil
  5. dbarale

    dbarale Squiddly slow

    Joined:
    Oct 20, 2008
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    1,338
    Location:
    Western NC
    Last shopping list...

    Needed:
    - <STRIKE>full gasket set</STRIKE>
    - <STRIKE>timing chain</STRIKE>
    - <STRIKE>GS500 front wheel</STRIKE>
    - <STRIKE>GS500 rear wheel</STRIKE>
    - <S>tires</S>
    - <S>mirror</S> (ordered)
    - <STRIKE>front cam chain guide</STRIKE>
    - <STRIKE>suspension linkage needle bearing and hem joint</STRIKE>
    - <STRIKE>seat cover</STRIKE>
    - <STRIKE>used gs500 sprocket to check gearing</STRIKE>
    - <STRIKE>rear brake caliper </STRIKE>
    - <S>15T front sprocket</S> (ordered)

    Wanted:
    - <S>XR style tailight</S>
    - <STRIKE>SM front fender</STRIKE>
    - <S>factory clutch perch and lever (the ratio on this one seems to be all wrong)</S> (ordered)
    - <STRIKE>maybe a lighter skidplate</STRIKE>
    - SS front brake line
    - fork brace (Where can I find one of these?)
    - baffle/insert for exhaust
  6. dbarale

    dbarale Squiddly slow

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    Oct 20, 2008
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    Probably my last post in this thread...

    I just love this bike. The new 15/45 gearing is perfect with the 140 rear, at least for my needs.
    I need to put thicker oil in the forks (too quick on rebound right now), tune the exhaust and the carb but I am otherwise done.
    I love this bike, it is just too much fun.
    The gas mileage seems awful but I have yet to rig a speedo to confirm and I honestly don't care.
    Did I mention I love this bike? :D
  7. GlennR

    GlennR Playin' in the Fire

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    Great thread! :thumb Subscribed.


    Does anybody know which years of the GS500 cush hub are thin? I think some are thicker, and don't want to buy any more "wrong" parts. :tough
  8. ben2go

    ben2go Moto Flunky

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    Jun 23, 2011
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    Location:
    Upstate SC USA
    They are all the same from 89-2011.There was no change.
  9. GlennR

    GlennR Playin' in the Fire

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    Cool. I can tell by your blog that you know your GS500's. I got it ordered & on the way.

    Thanks,:D
  10. dbarale

    dbarale Squiddly slow

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    Just for reference the measurement in red in the pic below is 42mm for the Katana sprocket carrier. 27mm for the GS500 carrier.

    Also the DR350S stock spacer between sprocket carrier and hub can be used as-is for the GS500 wheel. No need to machine another one...

    [​IMG]
  11. ben2go

    ben2go Moto Flunky

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    You're welcome.Thanks for checking out my blogs.I need to finish some updates.
  12. ben2go

    ben2go Moto Flunky

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    4,061
    Location:
    Upstate SC USA
    Good info.Thanks.
  13. dbarale

    dbarale Squiddly slow

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    Mo' brakes... Mo'tard...

    So at first we had this:

    [​IMG]

    OK for a dirt bike or just putting around. Not what I want on a motard.
    So I upgraded to this, GS500 rotor and DR350 caliper on home-made relocation bracket:

    [​IMG]

    Much better, but while the braking power was there the feel wasn't great.
    So here is the latest and greatest:

    [​IMG]

    Now we're talking. 1st gen Bandit 1200 caliper on another home-made relocation bracket. Big pads that use all of the surface of the rotor, 4 pistons so that the side loads on the bracket are minimal, much better feel and the pads are not even bedded yet! To the point where I'm wondering if I am going to switch to a stainless line as I originally planned. Might be a bit too touchy...

    [​IMG]

    Next pic is an attempt to show the clearance between rim and caliper. Kinda tight, about 15mm:

    [​IMG]
  14. B.Curvin

    B.Curvin Feral Chia tamer

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    I think the engineer types say "a mm's good as a mile".

    Or is it machinists that say that? :D

    I like that brake set up.
  15. GlennR

    GlennR Playin' in the Fire

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    The photo makes it look like 1-2 mm. 15mm is over 1/2", it looks a whole lot closer than that.

    But, you "obviously" know how to measure!!

    Good job. :thumb
  16. dbarale

    dbarale Squiddly slow

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    Yeah, the pic makes it look a lot worse than it is. I double checked and I can slide in the tip of my pinkie. So it's probably closer to 10mm. Just glad I won't get muddy with this one as it would definitely clog up.

    How is your motard conversion going? Any progress lately?
  17. mopo710

    mopo710 n00b

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    is that a 150 rear tyre and did it fit in the swingarm ok?
  18. dbarale

    dbarale Squiddly slow

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    No, it's a 140. See below...


  19. mopo710

    mopo710 n00b

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    ah ok, cheers for that-very helpful :)
  20. ohgood

    ohgood Long timer

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    Sep 21, 2010
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    Location:
    alabama
    it's too early to say if a dr440 is in my future or not, but we'll see.

    (revived for my own bookmarks, and to hear if this bike is still on the road)

    :clap