Kawazuki DuREX

Discussion in 'Some Assembly Required' started by yermaun, Sep 13, 2013.

  1. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    I started this build several months ago, merging a 1992 Kawasaki EX500 motor with a 1995ish Suzuki DR650,
    [​IMG]
    #1
  2. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    this was the donor[​IMG]
    #2
  3. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #3
  4. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #4
  5. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #5
  6. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #6
  7. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #7
  8. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #8
  9. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    Working on coolant system & exhaust right now, Trying to get this project on the road before the end of the year:D
    #9
  10. 4play

    4play Next?

    Joined:
    Feb 28, 2008
    Oddometer:
    2,639
    Location:
    Avondale, AZ
    Nice
    #10
  11. Pezz_gs

    Pezz_gs Cant ride for crap

    Joined:
    Nov 13, 2004
    Oddometer:
    3,874
    Location:
    Sydney Skunkworks
    Yermaun

    Looks great :clap

    I will be watching your progress :freaky
    #11
  12. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    I made some progress today on the exhaust, started with the donor V&H EX500 unit, chopped it off just under the right foot rest & used some old Yamaha FZ1 mid pipe & mated it to a ZX10R Yoshimura carbon slip on. Coolant system also installed using an EX650 radiator, Ready for the wiring harness now!
    [​IMG]
    #12
  13. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #13
  14. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #14
  15. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    [​IMG]
    #15
  16. bk brkr baker

    bk brkr baker Long timer

    Joined:
    Jul 19, 2006
    Oddometer:
    6,064
    Location:
    The Bluegrass
    The EX motor sure looks at home in that frame. There doesn't seem to be near fittment problems compared to the 650 Ninja/Versys swap.
    #16
  17. Lizrdbrth

    Lizrdbrth Wackjob

    Joined:
    Feb 21, 2006
    Oddometer:
    865
    Location:
    High desert, soCal
    Interesting. That motor is too tall for a KLR frame. It'll go in, but zero daylight between the valve cover and the top tube. You'd have to pull the motor to adjust the valves.

    Never woulda thunk to put it into a DR frame.
    #17
  18. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
    Aug 5, 2007
    Oddometer:
    1,749
    Location:
    Oakland, CA
    Nice! I sure plan to follow this one since I have a DR in bits AND a Ninja 650 in my shop!
    #18
  19. JerryH

    JerryH Banned

    Joined:
    Jul 4, 2009
    Oddometer:
    5,069
    Location:
    Chandler, AZ
    Way to go. The EX500 is a great motor. Unfortunately I found the EX500 too uncomfortable to ride very much. Nice to see that motor in something more rideable. Kawasaki makes the KLE500, unfortunately not for the U.S. market. And it probably has a detuned engine, like the Vulcan 500.
    #19
  20. yermaun

    yermaun Been here awhile

    Joined:
    Jun 11, 2010
    Oddometer:
    138
    Location:
    Cape Coral FL
    The motor was not without its fitment issues, the upper shock mount cross member had to be relocated to make way for the intake & the fuel tank had to be raised over an inch to clear the valve cover, I may have to replace the front wheel with a 17" wheel for rad clearance
    #20