Kawasaki 650 Thinja notes; parts bin build

Discussion in 'Some Assembly Required' started by dentvet, Jan 23, 2011.

  1. 4play

    4play Next?

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    Swing arm is done, should be plenty stout

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  2. 4play

    4play Next?

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    It rolls!
    The 950# spring rate feels pretty good jumping up & down on it in the shop.
    I didn't measure the sag, but it has some static & the race sag felt about right. I'm thinking about mounting the computer under the rear rack. I'm still trying to decide on a rear fender/tailight/license plate holder.

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  3. ktmklx

    ktmklx Been here awhile

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    Nice job on the swinger and the pegs, looking good!
  4. 4play

    4play Next?

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    Thanks, I appreciate all of you guys that led the way & shared your builds :freaky
  5. 4play

    4play Next?

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    I really don't like the ignition switch assembly, but it works, it's free & I hid it here for now. Still thinking

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  6. sanjoh

    sanjoh Purveyor of Light

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    +1, it's a dang heavy thing as well!
  7. dentvet

    dentvet Long timer

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    You are doing great on your mods and i love that bike stand that you rigged up. I kept thinking of stuff to do with that tube running through the center of the bike. you could store some full size roll up maps in that thing.

    This guy has a simple ignition switch on his rat bike

    http://www.advrider.com/forums/showpost.php?p=19849681&postcount=23
  8. 4play

    4play Next?

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    Thanks, it sure helped having a head start :evil

    Without the rubber bump stop figuring 2.75" of shock travel, I get just over 9" of wheel travel, using a more realistic 2.5" with the snubber compressed I get 8.25" :clap

    With the rather large 150/70-18" Mefo Super Explorer This is my clearance bottomed out.

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    Brake pedal is now lower, I trimmed the spacer to bring the guards in almost a 1/4" and reversed the bolt. I think the "fake brake" will be a non issue

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  9. 4play

    4play Next?

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    I was not happy with the flex I was getting at the pegs from the 3/16" steel plate being unsupported for ~4". I welded a 1/8" x 3/4" strap on edge on the back & they are rock solid now, no need for additional bracing. I had forgotten about the brake switch, looks like I'm going to have to use a pressure switch/banjo bolt. With the brace, I don't see a reasonable way to mount the original pull switch.

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    Foot controls are done! I'll paint the shifter assembly after I'm sure about it. I don't like the angle of the linkage, but it seems to function fine.

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  10. 4play

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    Extending the seat base. I've never worked with ABS before, now I'm thinking about using this stuff for the inner fender.

    I still need to trim & remold the bottom, but I'm getting closer.

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  11. 4play

    4play Next?

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    In hindsight, I think I should have brought the side farther forward but we'll see what they say.
    The ABS is pretty easy to play with.

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  12. jdrocks

    jdrocks Gravel Runner

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    fit the fender liner as tight as possible, or the top side will be loaded with dust and mud. make an ABS block off plate for the front of the swingarm to prevent mud and gravel being thrown forward. careful with the CPU mounting, without it, that moto ain't goin' anywhere.

    you'll like the extra fuel. supposed to be a 5 gal tank, but i put 5.46 in mine after running it dry last year...don't ask. the ER6 tank is supposed to be 4.2 gal, and i did manage to put 4.19 in that one once. the extra range with the larger tank is welcome.
  13. 4play

    4play Next?

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    The seat is in the mail to Fisher. Here is the inner fender, the 3/16" ABS is nice. I basically cut it to size, clamped it in place, put some 1/2" OD hose on top of the tire & heated the ABS with the shock bottomed out. Let it cool & it's done!

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    I'm going to add a couple of tabs to support it near the computer. As JD said, it ain't going nowhere without the computer. The rear fender will be made of aluminum, I have it laid out, very basic, utilitarian, I.m still thinking about "the look" but my fab skills only go so far...
  14. 4play

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    Looking at wind management

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    Not very pretty, but I belive it would be functional in ABS plastic.
    It would have rounded corners not creases like the cardboard

    Any better ideas?
  15. sanjoh

    sanjoh Purveyor of Light

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  16. dentvet

    dentvet Long timer

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    SJ, What is the best combo of lights you offer for running that dual setup?


    4play, i was going to suggest that you peruse the kitchen trash can section at home depot to see if there was a pre made fairing with stiffeners already to go in the size you showed in your picture. After seeing sanjohs option, i would be embarrassed to suggest that:deal

    Thinja is looking great from your hard work and ideas. Is your seat back yet?
  17. 4play

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    Hello Dave,
    Yeah, I hate to spend the money for the light, but I do like the fairing they designed. I use the 8" light on my smaller bike for night rides here so I already had it.
    I've had alot of fun playing with it, but I'm really anxius to start riding it.

    You did a really good job getting it to suit your needs, I'm tweeking your start a bit to suit my somewhat unusual requirements. Must be a reasonably capable long range trail/exploration bike, a reasonably comfortable two up weekend cafe cruiser & be something I will enjoy riding alone. It may even be used for some work commuting. My plan is to leave the engine/exhaust completely stock which is weird for me condsidering my 450 is 600cc's :huh

    The seat is still at Fisher's, I told them no rush. I'm still working out a rear fender & I'm re doing the sprocket/wheel spacer to have a boss fit on the 52T KTM Ironman sprocket I already had. Other than that. I'm ready to ride!

    I weighed the bike with everything except the rear fender & seat. It's right at 401lbs without fuel, so I'm expecting ~450lbs full of fuel ready to ride, more than I hoped, but still 100lbs lighter than a comparable KTM990 with suspension that I believe is just as good as a stock 990. I ordered .54kg front springs which should give the front forks a little boost.
  18. 4play

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    Rolled it outside to run it for a bit. I'm getting anxious to ride

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  19. 4play

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    After a failed attempt to bend some .090" aluminum into a rear fender using my welding table, I spotted a trailer fender for nearly free. It had a rolled edge on one side & a flange on the other so I cut a couple of pieces & welded them together, that let me get exactly the width I needed anyway.

    It's not real pretty, but it should keep the muck of me & more importantly the Mrs. The tail light/brake light also has amber led's that are the turn signals. It's very bright, but I'll probably add a couple of led's on the saddlebag mounts later..

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  20. sanjoh

    sanjoh Purveyor of Light

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    Most folks go with a pair of Model 60s. A ridiculous amount of light.

    The fairing has far exceeded my expectations it provides great wind protection, without buffeting, while not getting in the way in the knarly stuff.