V649HP-Kawasaki's new gravel runner

Discussion in 'Some Assembly Required' started by jdrocks, Dec 13, 2010.

  1. yokesman

    yokesman Been here awhile

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    is there any reason those bushes couldnot be just red loctited in without the shoulder. then some thin wall tube could be used eliminating the shop work.
  2. Bambi

    Bambi Been here awhile

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    Hello there,
    jdrocks replied:

    'these threads have been around for years at this point, so it's not front page news.

    the real story is the number of these bikes that do not show up in a build thread, of which there are many times more, although still a tiny fraction of the number of any half way comparable production bike.

    what Kawasaki does or doesn't do in the area of future design and production is not a concern of guys building these motos...if they wanted a bike off the showroom floor, they wouldn't be working away out in the shop.'

    All of this is true and untrue by the same time. In Germany, my country, for example you're not allowed to cut, re-design and weld a motor-cycle frame. You can do modifications, but usually just on the 'bolt-on-side' or it's a long and thorny road as you got to have permissions or documents for every little bit ...
    I don't worry too much about my own theory, being an elder bloke with limited skills and having found a few bikes I do like. I'm able to maintain and repair them and to make minor changes to get them nearer to my needs and likes. It's just been a thought, especially as I do like mid-sized off-road-twins very much. And I thought there would be some more people with these likes out there ... And, finally, I thought it would give some pride to those who built these bikes ...
    Kind regards, Bambi<!-- / message --><!-- sig -->
  3. jdrocks

    jdrocks Gravel Runner

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    there's more than one way to sleeve the lower clamp 1.5mm, but machining the sleeves per my spec is probably the easiest. this batch of sleeves was specced with a 4mm shoulder, heavier than the shoulder on the first set. this still allows the piece to self position and trim in place, and also helps it maintain shape. if the piece gets out of round for any reason, basically, you're screwed.

    if you find some tubing that runs exactly 49/52, let us know the sourcing.

    here are the first sleeves with a narrow 1mm+/- shoulder.

    [​IMG]

    [​IMG]

    new sleeves with a 4mmX60mm shoulder.

    [​IMG]

    lucky i made the change on the build sheet, i would have had a real tough time widening the slot otherwise. 1.5mm or .06 feels eggshell thin if ya have to do a little work on them.
  4. L.B.S.

    L.B.S. Long timer

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    It's interesting how quickly: "boy, this is pretty beefy" can change to: "ack, look how thin this is..." if you discover you need to do some more work on it. :lol3
  5. jdrocks

    jdrocks Gravel Runner

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    good deal, you're all set, ya can bolt together a V649HP without getting tossed in the big house.
  6. jdrocks

    jdrocks Gravel Runner

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    true, some restraint was necessary, my hands ain't exactly dainty.
  7. yokesman

    yokesman Been here awhile

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    Looking at www.emjmetals.com/PDF/BBook/Tubing and Pipe.pdf,
    calcing the difference in sae diameters and wondering about the shape of the
    bush after the slot is cut plus adding the fill factor of the red loctite why not just use these tubes as bushes. now I am using different triples on my suzie(50/54) but yet donot have them yet(still have the ninja triples)
    here are the numbers from the charts.
    2 inch with a .035 wall ,id = 1.930(49mm=1.92913,50mm=1.96850)
    2.125 with a .095 wall,id=1.935(.006 diff but what is the manufacturing tolerences on these tubes +/-.
    just trying to filter some info.
  8. MTrider16

    MTrider16 Ridin' in MT

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    Did your machine shop buddy try rolling sheet? .06 or .07 shim stock would roll up like a sheet of paper.

    http://www.mcmaster.com/#9500k19/=p3csng

    The nice thing about the shoulder, it doesn't try to slip out of the clamp while you are driving down the road.


    David
  9. jdrocks

    jdrocks Gravel Runner

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    anyone wanting to fab these sleeves themselves, or to use a jobshop for the work is welcome to explore any method or material they care to chose, but of the people who have contacted me about fabbing the parts, nobody has mentioned using anything other than 6061 schedule 80 pipe, the same material i use. nobody has asked for a CNC file, for instance, so the sleeves could be cut from a chunk of 6061. i've always said that these sleeves should be easy and cheap, and they are if you can do the work yourself, or find the right machinist. cheap means minimal setup, and fast production.

    [​IMG]

    [​IMG]

    [​IMG]
  10. jdrocks

    jdrocks Gravel Runner

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    never asked, not what i want.
  11. jdrocks

    jdrocks Gravel Runner

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    finally got back in the shop for a few minutes...

    frame prepped for paint.

    [​IMG]

    cleaned up the swingarm, sanded out some nicks and scratches. the parts bike was an 09 ER6, so i didn't have to source one of these late model swingarms.

    [​IMG]

    the 06-08 swingarms have a rectangular section, whereas the 09 has a D section, so they are easy to distinguish. "D" section is the stronger of the two.

    [​IMG]

    set the adapters in the lower Versys clamp with some cylinder sleeve adhesive.

    [​IMG]

    the slot in the adapter lines up with the clamp. the adapter is .5mm shorter than the clamp so that the adapter seats perfectly to the shoulder.

    [​IMG]
  12. MTrider16

    MTrider16 Ridin' in MT

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    How is your painter doing this time around? :wink:

    David
  13. jdrocks

    jdrocks Gravel Runner

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    i had a feeling someone would ask.
  14. jdrocks

    jdrocks Gravel Runner

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    i got around to spraying some parts so i could start bolting the new bike together. i would say painting, but that would tend to malign any spray painter who actually knows what the heck he's doing.

    anyway, the frame is painted...more or less. this frame was no easier to paint than the last one, haven't learned a thing i reckon.

    [​IMG]

    i know one thing, it's not the paint. i've looked at all kinds of different paints and sources when purchasing paint, but i've stayed with the Summit Racing branded automotive paint in urethane. it's inexpensive as paints go, and if you get somewhat competent spraying it, it's sorta the poor man's powder coat, a very durable finish. this frame is sprayed Hot Rod black in a medium luster finish, same as the last one.
  15. MTrider16

    MTrider16 Ridin' in MT

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    In your defense, that doesn't look like a very easy peice to paint. :thumb

    David
  16. jdrocks

    jdrocks Gravel Runner

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    frames aren't easy, and you're also fighting certain characteristics of urethane paint.

    the best way would be to mount the frame on a rotating engine stand as suggested by ktmklx, ain't got one of those in the shop.

    one thing i do know about spraying this kind of paint, forget about trying to spray in a cool shop, won't work worth a damn.

    i asked a body shop man what kind of temp he likes for this paint, he said "about 100 degrees". well, ya don't need 100, but you get the idea.
  17. jdrocks

    jdrocks Gravel Runner

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    gotta get some wheels under this thing...swingarm and clamps mounted.

    [​IMG]

    as mentioned earlier, the 2009-11 ER6 swingarm comes with the OEM hugger and blockoff plate, two more necessary items crossed off the list. if using this swingarm, you need the whole assembly because the axle, axle pads, and adjusters are not the same as the 2006-08 parts.

    the ignition switch was removed from the ER6 top clamp and installed in the Versys top clamp. the OEM installation mounts the switch with what looks like a pair of rivets, but they're really threaded fasteners with a security head. the heads need to be removed so the switch can lifted out, then the remaining studs can be gripped with a channel lock or similar. don't mess it up.
  18. jdrocks

    jdrocks Gravel Runner

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    i have a shock, but i need to do a little work on it before it gets mounted, no problem, i threw in a temporary strut with the same mounting centers so i could keep going.

    [​IMG]
  19. jdrocks

    jdrocks Gravel Runner

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    with the strut in place, i could drop the swingarm onto a paddock stand, support the front, and mount the huge 49mm DRZ conventionals in the Versys clamps. the forks project 20mm from the top of the clamp to the fork cap, a good starting point for the suspension setup.

    black DRZ forks are very hard to find...

    [​IMG]
  20. MTrider16

    MTrider16 Ridin' in MT

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    A suspicious person might ask if they have Summit Racing Hot Rod Black urethane on them. Of course I'm not a suspicious person. :wink:

    Looks like a great start, although procuring parts has taken considerable time already.

    On a side note, I think I took the big Honda for its last ride of the season. Man, she just begs to be taken over a ton, just twitch of the wrist...

    David