My own DR650 mod thread

Discussion in 'Thumpers' started by Gustavo.Ramos, Feb 23, 2010.

  1. Gustavo.Ramos

    Gustavo.Ramos Been here awhile

    Joined:
    May 19, 2008
    Oddometer:
    975
    Location:
    Accross the pond
    Hi,<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
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    After a few months absent due to unscheduled events, looks like by the end of 2009 the planets are aligned enough to restart my Project.<o:p></o:p>
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    Almost one year colecting parts, searching, reading, cursing i finally did a few mods to my mature DR650SE ’97.<o:p></o:p>
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    I apologise for my English, but as someone once told me “you sure speak a lot better English, than most here speak Portuguese!”. :evil <o:p></o:p>
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    Some items to be covered:<o:p></o:p>
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    Exhaust<o:p></o:p>
    Engine<o:p></o:p>
    Suspension<o:p></o:p>
    Lighting<o:p></o:p>
    Protection<o:p></o:p>
    Comfort<o:p></o:p>
    Range<o:p></o:p>
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    Here it is… before:<o:p></o:p>
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    [​IMG]<o:p></o:p>
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    Practically bone-stock with na extra 130.000 kms of (ab)use by me and 2 or 3 other previous owners.<o:p></o:p>
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    Firt step: Exhaust<o:p></o:p>
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    Out with the stock one, let’s get a GSXR. I didn’t had the 2000/1 1000 gixxer can, so i used the 750 counterpart. Yes a bit heavier, and the sound isn’t he same either, but still much better than stock anchor<o:p></o:p>
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    Link pipe was done in stainless steel by a local. <o:p></o:p>
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    Nothing too scientific:<o:p></o:p>
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    Front Forks<o:p></o:p>
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    As Lukas already did on His DR650, i followed His excellent work. However firt I managed to get some progressive springs, but who was I kidding? WP forks rule! :lol3 <o:p></o:p>
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    Got a nice deal with forks, brake calyper+master cylinder, wheel, rotor and a good tire.<o:p></o:p>
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    Only needed the handlebar and triple clamps. Manageable too! <o:p></o:p>
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    However nice deals sometimes pose a few surprises:<o:p></o:p>
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    Need a complete rebuild, oil was low and seals dead.<o:p></o:p>
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    Ups... Washer that holds forks inner tube and outer tube in one piece. On was ok (flat) the other, a bit more and someday the tubo would comeout. Not good.<o:p></o:p>
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    Improvising<o:p></o:p>
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    OhOh…. :huh <o:p></o:p>
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    Bad sign, the hidraulic was toast, but i managed to get it back to life<o:p></o:p>
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    Home made seal fitting tool.:<o:p></o:p>
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    Triple clamps… in <?xml:namespace prefix = st1 ns = "urn:schemas-microsoft-com:eek:ffice:smarttags" /><st1:City w:st="on"><st1:place w:st="on">Orange</st1:place></st1:City>!?!?!?!!!?!? :puke1 <o:p></o:p>
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    Before:<o:p></o:p>
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    Aircraft paint stripper!:lol3 <o:p></o:p>
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    Oh baby… (in a matter of few minutes):rofl <o:p></o:p>
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    Assemble.<o:p></o:p>
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    Old forks:<o:p></o:p>
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    And increased bar height, a few extra 50 mms. <o:p></o:p>
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    Then i noticed the stock headlight mounts would not fit, and i needed to go for a ride. <o:p></o:p>
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    So i got this really stinky solution :huh <o:p></o:p>
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    Bah… but at least i have lights and cops won’t bother me…too much.:wink: <o:p></o:p>
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    The engine<o:p></o:p>
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    After 12 years of (ab)use, billions of strokes, thousands of fuel liters, 3 or 4 owners, 130.000kms, engine started giving up… Oil burning, vibration, gears jumping off, etc.. not good.<o:p></o:p>
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    And the 3rd gear ghost always around me made do the correct thing before the engine would go out with a big bang… in the middle of friggin nowhere… and since the 3<SUP>rd</SUP> gear was getting worse by everyday… it was time.<o:p></o:p>
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    It was time for a big mistake. Had to wait 4 months to get all the necessary parts to rebuild the engine. Unbelievable… Next time I’ll order these in <st1:country-region w:st="on"><st1:place w:st="on">Germany</st1:place></st1:country-region> to Stefan Hessler, or get them directly from the states.<o:p></o:p>
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    Live and learn!:deal <o:p></o:p>
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    Ended up with few pictures and i somehow lost a memory card..<o:p></o:p>
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    The condition of one of the gears (not the 3rd one)<o:p></o:p>
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    Overview<o:p></o:p>
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    After assembling, it fired right away!<o:p></o:p>
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    Clear increase in torque, power and smoothness<o:p></o:p>
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    Took the time and shimmed the head by <st1:metricconverter w:st="on" ProductID="0,7 mm">0,7 mm</st1:metricconverter>, just to increase compression a tad bit!<o:p></o:p>
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    Then 1000 kms of break in…<o:p></o:p>
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    By the end of these 1000 and a few hundred more, everything was retightned and also too the chance to install a different camshaft.<o:p></o:p>
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    [​IMG]<o:p></o:p>
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    Result? Quite interesting!:lol3 <o:p></o:p>
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    Lighting<o:p></o:p>
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    The previous lighting solution sucked. <o:p></o:p>
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    I remembered I had somewhere a headlamp from a Suzy SV1000N. With it I also found a Givi winshild, that would be useful for longer distance rides<o:p></o:p>
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    So i needed to do some mountings.<o:p></o:p>
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    A bit basic yes…<o:p></o:p>
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    And the result.<o:p></o:p>
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    Not exactly what i had in mind, but for now… will do.<o:p></o:p>
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    Rear suspension<o:p></o:p>
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    While looking for alternatives i came accross this WP shock for a KTM… which KTM!? I don’t know. Neither the seller knew as he told me he had bought it for his 640 and was too big. <o:p></o:p>
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    The stock DR650 rear shock measure 45 cms between axles, this one was 46 cms. Maybe I could benefit from a few extra cms!<o:p></o:p>
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    Price was too good to pass by so I snagged it.<o:p></o:p>
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    Stock vs WP<o:p></o:p>
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    Small adjustments required<o:p></o:p>
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    Overal height increase was 4 cms<o:p></o:p>
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    Got a CRD bash plate too. <o:p></o:p>
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    Didn’t come with mountings so I had to build them<o:p></o:p>
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    [​IMG]<o:p></o:p>
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    Only after going for a ride i really noticed how much stuff hits the cases. Never heard of that pinging sound before.<o:p></o:p>
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    Also found something i wanted to try. A wider exhaust header<o:p></o:p>
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    Disassemble<o:p></o:p>
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    Compare<o:p></o:p>
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    4,5 mms wider!:deal <o:p></o:p>
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    Before:<o:p></o:p>
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    After<o:p></o:p>
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    It’s a bit noisier… can feel some difference with médium to high revs, but low end is a bit softer, maybe due to lower back pressure caused by wider tube<o:p></o:p>
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    Range<o:p></o:p>
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    The choice was the Acerbis 28~30 Litre that is fitted on the KTM 620/640 Adventure. With the tank i got the seat too.<o:p></o:p>
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    This tank fits quite well into the DR frame and tank mountings, i had to do little cut and paste.<o:p></o:p>
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    Some rubber mountings (highly scientific)<o:p></o:p>
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    Fittings and available room:<o:p></o:p>
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    Central fitting.<o:p></o:p>
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    Side fittings.<o:p></o:p>
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    Due to tank size, the petcock is considerably lower than the carburetor, so i choose to get a fuel pump. This time was a Mikuni from a SV650... :rofl <o:p></o:p>
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    With the new seat i also had to do some mounting mods and relocate the ECU<o:p></o:p>
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    Current status<o:p></o:p>
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    Before…<o:p></o:p>
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    And after:<o:p></o:p>
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    Testing indicates the bike i quite comfortable, not hard considering the dreaded seat from hell the stock DR650SE has, engine response is quite good, handling is much better, WP’s really make the difference. Bike is high!!:lol3 <o:p></o:p>
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    Later will get a TM40, decent lighting, roadbook, GPS, etc…<o:p></o:p>
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    Thanks to all who helped with tips, research, and their own invaluable projects!<o:p></o:p>
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    To be continued… :evil

    Gustavo<o:p></o:p>
    #1
  2. Kilo Sierra

    Kilo Sierra Been here awhile

    Joined:
    Jan 2, 2006
    Oddometer:
    189
    Location:
    Wasilla Alaska...a house in the country.
    Nicely done.
    ks
    #2
  3. hscrugby

    hscrugby "That guy"

    Joined:
    Jan 11, 2010
    Oddometer:
    4,099
    Location:
    Raleigh, NC
    Looks really nice. Except that light. :D
    Not sure why the light bugs me, but it does. But it sounds like that's a temporary (And I'm sure better lighting) solution.

    Anyway, how'd you go about making the mounts for the skid plate? Got any more pics of that, or where it actually mounts? I'm in the same boat, have skid plate, and no mounts.

    Thanks
    #3
  4. SeanF

    SeanF -

    Joined:
    Jun 11, 2004
    Oddometer:
    2,190
    Location:
    Tucson Arizona USA
    .
    :lurk
    #4
  5. Gustavo.Ramos

    Gustavo.Ramos Been here awhile

    Joined:
    May 19, 2008
    Oddometer:
    975
    Location:
    Accross the pond
    Thanks! Yes it is temporary, untill i get the front end ideias sorted out.

    Regarding the mounts for the skid plate i used the 2 rear screws on the frame and 2 brackets on the front. All with a thick layer of rubber.

    The mounts:

    [​IMG]

    And before being tightned:

    [​IMG]

    Sorry, don't have other images, but that will give you a starting point.

    Edit: spelling
    #5
  6. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,429
    Location:
    On a RTW ride - currently SE Asia on the way to OZ
    Hey Gustavo,

    Good to see that you are still around. After the troubles with the forks leaking and the engine being done I thought you had given up on the ole' DR. Didn't you also buy a 950 Adv?

    Great build up so far, I like the innovative solutions. Finally somebody has detailed what it takes to fit the 28L KTM tank, those will be a much cheaper source than the Safari supertankers. Now you also have a great base to slap a 640-Adv front fairing and lights on there! I assume you have seen Ron's awesome build where he used one? :thumb

    What did it take to fit the WP shock? I have a couple of those lying around, they are not worth much to KTM people as they come stock on lots of them. But for the DR it should definitely be a nice improvement.

    By the way, the ring from the forks sure looks familiar. I found the same in a set of SX forks I rebuilt last year. Must have been pounded pretty good! :eek1

    [​IMG]
    #6
  7. Ron Seida

    Ron Seida Adventman

    Joined:
    Jan 24, 2005
    Oddometer:
    1,260
    Location:
    Home sweet Home!
    Awesome build Gustavo, and like Lucas pointed out, very innovative :thumb.
    One thing i would like to point out. Your fuel pump and lines are very close to the cylinder, vapor lock may become a problem in hot climates. You might want to consider either shielding it with an aluminum heat sink, or find a new home for it. Keep up the good work, i look forward to your lighting solution :lurk.
    #7
  8. DisTech

    DisTech Been here awhile

    Joined:
    Sep 3, 2008
    Oddometer:
    616
    Location:
    Seattle
    Many interesting choices. Nice work! :lurk
    #8
  9. dylandr

    dylandr Been here awhile

    Joined:
    Jan 5, 2009
    Oddometer:
    204
    Location:
    South Africa
    Brilliant work! You guys are all evil! If I stay on ADV I'm never gonna stop farkling bikes!
    Good job, Keep it coming!

    Cheers Dyl:thumb
    #9
  10. wangiles

    wangiles Adventurer

    Joined:
    Sep 10, 2009
    Oddometer:
    10
    Huh? no more updates? :lurk
    haha. Nice built up. Was looking for a change of bike. Am contemplating on a dr650 too..this gives me new perspectives. totally. haha. More more! :D
    #10
  11. peteandheidi

    peteandheidi Been here awhile

    Joined:
    Feb 2, 2008
    Oddometer:
    407
    Very interesting...just a couple of questions as im going to be mounting the same forks soon.

    Did you just retain the suzuki bearing cups and use the ktm stem and bearings???

    What did you do about the steering stops???
    #11
  12. JensEskildsen

    JensEskildsen Long timer

    Joined:
    Mar 24, 2009
    Oddometer:
    1,086
    Location:
    Denmark
    Thats some really nice work, I love the whole "that doesn't fit, lets make a bracket for it, and fit it anyway" approach :evil

    Very inspiring. :ear
    #12
  13. DRjoe

    DRjoe Long timer

    Joined:
    Sep 6, 2007
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    5,330
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    Sunshine coast qld
    bloody awesome mate your a legend.
    #13
  14. Gustavo.Ramos

    Gustavo.Ramos Been here awhile

    Joined:
    May 19, 2008
    Oddometer:
    975
    Location:
    Accross the pond
    Hi Lukas,

    Yes i've been a bit away... other priorities. Main problem with forks was leaking o-rings, but that was solved! Engine parts availability was a nightmare too... never again.

    Not yet on the 950, maybe a 990 soon...

    I'm quietly following a number of DR build threads, and some KTM 640 with kwak engines, etc.. :wink: , i also have a full 640 Adv fairing ready in my garage with brackets and lighting too, but i find it to be quite heavy. I'm thinking about a mixed solution where i can have 2 set ups available with little hassle.

    To be honest i just had to add 3 washers on the top axle, 2 on the left side, 1 on the right side.

    Same thing below, 3 washers a longer bolt with locking nut and it's done. :D

    I'll dig into that however all the fuel lines i used are reinforced a double layer of non rubber fabric that helps to protect from elements and heat.

    I tried another location, but nowere else seemed to fit (at all). But i'll have a look for a heatsink.

    Thanks! Don't leave ADV, whats the fun about not farkling bikes!? :evil

    Yes, same bearing cups from the DR and KTM bearings. Have a look at LukasM DR650 Build thread.

    So far i do not have them, but these will be done by applying 2 rubber inserts on each sid of the fuel tank side brackets. forks go directly there!

    Thanks! Have you looked at your DR thread recently!? :deal
    #14
  15. ADVCoop

    ADVCoop Been here awhile

    Joined:
    Aug 22, 2007
    Oddometer:
    798
    Location:
    Acme, PA
    Very organized and clean rebuild, I like that :D . The bike looks good!
    #15
  16. TheFrenchCanadian

    TheFrenchCanadian Frog Prince

    Joined:
    Oct 26, 2007
    Oddometer:
    148
    Location:
    Saskatchewan, Canada
    Awesome! Keep up the good work!
    Subscribed... :lurk

    TFC
    #16
  17. LexTalionis

    LexTalionis Inciteful

    Joined:
    Nov 3, 2008
    Oddometer:
    452
    Location:
    San Jose, CA
    Thanks for the entertainment and education, well done.

    Lacking your expertise there is much of what you have done that is outside my abilities. However, for me, the first thing I'd have done would be to take a pressure washer to the bike once the tank and side panels were removed!

    Lex
    #17
  18. handirifle

    handirifle Been here awhile

    Joined:
    Aug 24, 2008
    Oddometer:
    450
    Location:
    Central Coast, CA.
    Interesting build, you are definately making it your own! I have a suggestion, for the loss of low end grunt.

    Take a page from sportbike design. The kawasaki Ninja uses a computer controlled baffle in the exhaust. The baffle is closed during the lower part of the RPM range, and opens as revs climb. This provides the needed back pressure at lower RPM's and opens for a more free flow during the top of the band.

    You might look into the old baffle systems used on autos that were just off the manifold. those are crude, but might make an improvement. this same concept was addressed by 2 stroke bikes with the movable expansion chamber (muffler). It actually grew longer as RPMs climbed, allowing for more torgue at lower RPM's.
    #18
  19. Gustavo.Ramos

    Gustavo.Ramos Been here awhile

    Joined:
    May 19, 2008
    Oddometer:
    975
    Location:
    Accross the pond
    Heard that before :D

    Thought about that too, but the loss of low end is hardly noticeable. It's just *that* feeling, when you know your ride quite well! But if i run out of farkling ideias i'll do it! Like an EXUP valve! :wink:
    #19
  20. Gustavo.Ramos

    Gustavo.Ramos Been here awhile

    Joined:
    May 19, 2008
    Oddometer:
    975
    Location:
    Accross the pond
    First riding results

    Bike is seriously high, i'm 6 foot tall and i'm having a hard time to keep balance at stand and while doing some very slow maneuvres. Suddenly i found there is this strange world of short legged people... already made me fall once and a few "almost...".

    Fully fueled the extra weight is easily noticeable. Used to 13 liter fuel tank, now it goes with 28L. It's good the tank goes really low, that helps with center of gravity, but still weight is an issue.

    Went for a ride in mud and sand, bike feels really strong, lots of torque, well balanced, grip is good, and the suspension works like a dream when compared to the stock POS.:deal

    The seat is absolutly GREAT :clap ! i should burn the old stock DR seat.:lol3

    The final transmition feels a bit short, i'm running 15-43, engine feels quite revvy in 5th gear.

    Only one picture, we've had a sort of blizzard last weekend and it was windy, can't really tell that from the picture, but there was lots of sand in the air.

    [​IMG]

    The little mug in the pic insisted on trying to bite me. Don't think he likes the color.
    #20