DR650 Street Tracker Build

Discussion in 'Some Assembly Required' started by JagLite, Jan 20, 2013.

  1. JagLite

    JagLite Long timer

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  2. JagLite

    JagLite Long timer

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    I finally was able to start the tracker up this week.
    (we are buying a house and moving...)
    It ran terrible and sounded worse. :eek1

    I pulled the carb off and it was all gummy inside.
    After cleaning it out and reinstalling it, the engine runs much better but I will need to spend some time tuning it.

    It is super loud even with the new Emgo reverse cone megaphone muffler.

    I pulled the muffler core out and I discovered the reason why it is so loud...



    Can you see the problem?




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    How bizarre!
    Almost no packing in there at all.
    Only a tiny fragment against the end cap.
    It was all clumped together like paper mache' too.
    The muffler was brand new with not a scratch or finger print on it when I bought it.
    I doubt I ran the engine more than 3 minutes total before pulling the core out.
    But the wire wrap that holds the fiberglass packing is wound around the core.
    It's a mystery!

    Too bad I threw a large trash bag of leftover house insulation away.
    But I have friends building a house so I will pick up a few scraps to pack it with.

    Next winter I will weld up a new pipe so I can get rid of the ugly weld pipe with mummy wrap and I will probably weld on a flange and use a GSXR muffler instead.
  3. Pablo83

    Pablo83 Sleep, Wrench, Ride

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    I used two Emgo reverse cone mufflers on my tracker build.

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    They came as spare parts with a bike I got from my father-in-law. He said they were short on stuffing as well. I don't think I posted this in my build thread, but the mufflers were stupid-loud. They made it annoying to ride the bike. So I pulled the cores and bought some perforated pipe that was the same dia as my pipes (the Emgo cores where bigger than I needed) and made some new cores.

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    With smaller cores and more room for packing I thought it would really cut down on sound, but it did almost nothing. Later I added spark arrestors so I could legally ride it in the national forest and they really helped with the sound. They also helped with some mid-RPM power loss that I was experiencing.

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  4. MrPulldown

    MrPulldown Long timer

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    Are those sink strainers. NICE!
  5. Pablo83

    Pablo83 Sleep, Wrench, Ride

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  6. MrPulldown

    MrPulldown Long timer

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    They probably do need to be tougher

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  7. ADVwanaB

    ADVwanaB BOLD NEW AVATAR

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    how do you plan to lower the rear?
    what did you use for spacers on the front to lower it?
    I would like to lower my DR about the same as you have and install a 19" front wheel. It has to be balanced though right? or the rake will be too steep.
  8. JagLite

    JagLite Long timer

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    Rear lowering:
    When I had Cogent Dynamics rebuild the stock shock into a double clicker with full adjustment I had him internally limit the travel to about 8" (at the wheel).
    Then I had him install an adjustable height bottom clevis so I can play with ride height.
    I have it set so the rear end is about 3" lower than stock.
    Ride height is different from stock since the removable subframe and TT seat are lower than the stock frame and seat.
    That means my seat is lower than a stock bike would have with the factory lowering.

    Front lowering:
    I used steel tube that I had on hand for the fork spacers.
    Thick wall PVC or ABS could easily be used and is cheap and light.
    The spacers only limit the travel and are under very little load.
    The original top-out spring is still retained on the damper rod with the new spacers so that there is no instant hit against the spacers.
    There is a little load on the spacers when the forks are fully extended when jumping or doing a wheelie.

    Keep in mind that the stock spring is too long to put longer spacers (than the stock ones) in.
    The problem would be that you could not push the spring down enough to install the fork cap. :eek1
    So, depending on how much you want to lower your bike, the spacer you will use on the damper rod to limit upward travel will determine how much of the stock spring you will want to cut off.
    An easy way would be to figure your desired front end drop, install a spacer that length on the damper rod, reassemble the fork leg and drop the spring in.
    Then mark the spring at the top of the fork tube, take it out and cut it off at that height.
    Cut the tight coil end and this will make your forks stiffer and enable you to still play with preload spacers on top of the spring if you want.
    You can cut the springs shorter too if you want.

    If you are going to cut more of the spring off than the length of your limit spacers, be sure to figure out coil bind length using this chart:
    http://www.calsci.com/motorcycleinfo/Suspension2.html

    If you are using aftermarket fork springs which are usually (always?) shorter than stock for the DR you may not need to cut them and I wouldn't recommend cutting them.
    At least until after you have ridden it and see how stiff they are for your weight.

    Balanced lowering is a good start for handling.
    You may find you like the front lowered more than the rear as that will make the steering quicker or a bit more twitchy feeling.
    The motard bikes drop from a 21" wheel to a 17" wheel on the front and most don't lower the rear to compensate.
  9. shwaz

    shwaz Buckethead Wendy

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    holy freaking drooling green with envy. and my initials are AJS, too...

    this is one of the coolest things i've ever seen
  10. anotherflyer

    anotherflyer n00b

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    Very impressive.
  11. rhino_343

    rhino_343 Southern Explorer

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    Love it mate! Very inspirational and a timely read as I am looking to start something similar with my mate... Thanks for taking the time to write all this up and once again well done, you deserve that first place trophy! :clap
  12. NC Rick

    NC Rick Cogent Dynamics Inc

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    The bike is stunning! Awesome work!

    With regard to lowering, folks should keep in mind that smaller front wheel reduces trail, as will lowering the front without doing the same to the rear. Trust that you will want all the trail you can get when using a 17" wheel:evil
  13. JagLite

    JagLite Long timer

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    Thanks for the kind comments, I do appreciate it!

    I have been extremely busy fixing up an older house we bought and will start moving into this weekend so I have neglected posting on this thread.

    So, here are a few pictures of the bike after my first ride on a dirt road.

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    In this picture you can see the shock sock my wife sewed up for me.
    It has a Velcro seam so I can easily remove it for adjustments.

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    I like the reflection on the tank in these shots :D

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    Front views:

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    Heard the old term to "Drop it in the weeds" referring to lowering a car?

    So I did:

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    You may be waiting for a ride report, if so, wait a bit longer :lol3
    My short ride is not enough to test it out and give it a real workout, let alone adjust the suspension to my liking.
    I can say that it feels tiny!
    More like my Yamaha TW200 than anything else.
    Since I am 6'-4" it will take some getting used to I can tell.
    The 13/46 sprockets really give it instant acceleration and quick shifting.
    I plan to get a 14, 15, and maybe a 16 front sprockets to experiment with. But this is not a highway bike so I am not looking for a comfortable 65 mph cruise. :evil

    I am not happy with the muffler though. It is OK at low revs and sounds great but once up to even half throttle it is too loud. I don't like obnoxiously loud bikes making non-riders hate riders so I will be modifying the muffler or replacing it with a GSXR can.
    I am also going to make a new pipe since I didn't like my first attempt in both welding and in bend layout. The goofy mummy wrap covers the lousy welding but nothing can hide the shape not following the frame bends enough for me.

    Other than all the work fixing up the house we bought and the pain of moving everything and then fixing up our old house to get it on the market, I am looking forward to having a real shop.
    Yes! A two car garage (24'x24') instead of a one car garage...
    I am doubling my shop space! :clap
    This winter I have two project bikes lined up in addition to the Rickman Metisse.
    A Wee Strom 650 and a Suzuki VX 800.
    Tracker or cafe', or???? :wink:
  14. Lizrdbrth

    Lizrdbrth Wackjob

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  15. JagLite

    JagLite Long timer

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    Here are some interesting pictures comparing the Yamaha TW 200 with the DR 650 Tracker.

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    This should give everyone a good idea of how small the Tracker is :clap

    Now I need to take pictures of the Tracker next to my other DR for comparison. :eek1
  16. EvanADV

    EvanADV Big Bearded Boy

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    :deal
  17. JagLite

    JagLite Long timer

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    Finally took the time to shoot pictures of the Tracker with my DR.

    In the process of moving and I had to move the bikes to get at other stuff to load so I parked the bikes together and here is the results.

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    Switched positions:

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    And with the TW also:

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    While I was moving bikes out of the way I decided to take a few pictures of the Street Fleet together.
    These are the street legal bikes I currently have, although my Honda VTX1800 project is not in the pictures, yet. :evil


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    Not in the pictures are the dirt bikes.

    I should mention I only buy cheap bikes.
    My DR was the most expensive at $3,500.
    The TW was second at $2,200.
    The Wee Strom and VX800 are both future project bikes.
    The Wee was an insurance total sold as parts.
    The VX800 was $800 and the second one I have owned.
    I think it will make a neat and unique Street Tracker.

    Why buy new when I can buy 3, 4, 5 or more great bikes for less than the price of one nice new one. Well, I do want a Honda Grom... :lol3
  18. DRjoe

    DRjoe Long timer

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    Mate you've finished that bike of brilliantly.
    Its amazing how much slimmer it is compared to the stock dr.
  19. JagLite

    JagLite Long timer

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    Thanks for the suggestion!
    I sent some low res pics to both to see if one or the other would be interested in featuring it.
    Well, it has been two weeks and still not a word from either one.
    Which is the answer obviously. :cry
    My bike doesn't meet their requirements I guess. :huh
    Maybe the seat looks too comfortable? :poser

    Ah, well. I like my bike and I certainly enjoyed the build process and look forward to my next project.
  20. PhiSig1071

    PhiSig1071 What's ******width?

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    I'll be looking forward to it too. What's the plan with the Strom?