V649HP-Kawasaki's new gravel runner

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

  1. jdrocks

    jdrocks Gravel Runner

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    yeah, get it done for LF. there might be a few other home brewed bikes there. we'll run them around, see how they do.
  2. freewheeler

    freewheeler Been here awhile

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    I remember that ... I was thinking about the temp difference between Alsaka ... and Mexico ... In July ... anything will over heat if there is no air flow thu the radiator ... I was down your way last summer ... and the fan on my versys quit working ... sitting in traffic ... 90 degrees out ... my light went on and she puked her guts right there ... I rerouted to a less traveled road and kept air flowing thru the radiator ... made it home without a hitch ... ebayed a used fan from a ninja for $30.00 ... installed on the Versys mount ... back in business ...
  3. jdrocks

    jdrocks Gravel Runner

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    you must remember that old ride report from 2009. man, that was a trip.

    different part numbers on the 650R fan and Versys fan that i have, but the size, configuration, and electrical connector are the same. the mounts are different as you know, but other than that, i have no idea why the fans have different numbers.
  4. jdrocks

    jdrocks Gravel Runner

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    i need footrests, and after looking at some other options, i got out a set of Versys mounts. i got these to use on the last 650R framed bike but never got around to using them because i would have needed to change my fuel can mounts before i left for northern Quebec and Labrador. ran out of time.

    i had a pair of those nice Fastways, so i'll use those too.

    [​IMG]
  5. freewheeler

    freewheeler Been here awhile

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    That will make a nice combo ... Those foot pegs are like floor boards ...!!!
  6. dentvet

    dentvet Long timer

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    i'm fitting the rear wheel. If you can tell from your skeletons there, are the swingarm ends equidistant to the bikes centerline?

    my subframe is tweaked and i'm having trouble centering the wheel because the swingarm isn't symmetrical with the offset shock etc.

    I have found it interesting that a 19 inch dirt rim has spoke/rear caliper interference issues but the 18 inch dirt rim doesn't.
    ( i was toying with 19/19 at one point) the 19 inch motocross tire looks awful as well
  7. fredgreen

    fredgreen Proud Canoodian

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    Now you have my attention....How much of a project...I am interested now. My KLR is in the garage right now stripped down for a desert cam paint job. I just finished doing engine work and carb mods. Send me a PM if you really want to talk business.
  8. jdrocks

    jdrocks Gravel Runner

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    since you have your OEM wheel, axle, spacers, and caliper mount, that's all you really need to set up the new wheel because it gives you all relative dimensions...other than making sure the new wheel/tire combo doesn't have interference issues with the front of the swingarm or fender liner. the only alignment problem would come from a bent main frame (very unlikely) or bent swingarm (also unlikely).

    shouldn't be too difficult to pull the subframe back in shape.

    PM on the way with a contact number. i'm in the shop, so i could take a look at any measurements for ya if needed.
  9. jdrocks

    jdrocks Gravel Runner

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    the Versys has a 12mm pin and these used Fastways are set up 10mm. fix that and a little trimming, should work. i like the Fastways because of the adjuster bolt on the underside, you can dial them in easier.
  10. jdrocks

    jdrocks Gravel Runner

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    i'll try to get a PM out to you this evening with a photo.
  11. jdrocks

    jdrocks Gravel Runner

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    520 steel sprocket to replace the OEM 525 on the SV650 rear wheel.

    [​IMG]

    this sprocket is readily available because the 520 conversion is real popular with the SV crowd, they think making that change is worth some speed.

    i ordered a 46T to match the original Versys/650R gearing.
  12. BuffWv

    BuffWv Long timer

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    What do you think about a DRZ/KLX set of forks
  13. jdrocks

    jdrocks Gravel Runner

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    are you talking about the 49mm conventional, or say the smaller KLX USD forks? you already know the length of the 49mm, an older set of KLX 43mm USD forks is about 34", the same as a late model KLR.

    the nice thing about the DRZ for my purposes is the 20mm axles because the wheels i use have 20mm bearings.

    you would want to look at the fork/axle/bearing/wheel setup if it's not all from the same bike. long forks would mean getting a different shock setup, but that's usually not a big problem
  14. BuffWv

    BuffWv Long timer

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    Trying to work out a deal on the front forks and rear shock off a 2003 400
  15. dentvet

    dentvet Long timer

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    thanks for the number! you're right it all starts with the sprocket alignment and the rest must flow from there. I'm stuck at about 9mm off center for the rear tire after shimming the sprocket.

    started on the front legs, yz triple clamps meet ktm 43s. so far so good
    [​IMG]
  16. jdrocks

    jdrocks Gravel Runner

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    gave up on the 36mm forks and went directly to the 49mm beef? same forks and shock as your KLX, so you must have taken some measurements. the 2003 is fully adjustable if i remember.

    will be tall, but no taller than the current generation of 250 thumpers.

    i dropped DRZ forks in the clamps about 15mm before i tightened things up yesterday, leaving a 25mm projection. the rat is every bit as tall as my WR250. the mofo is way the heck up there for a "street" bike. makes the OEM roller frame from the 650R parts bike look like a lowered drag bike project.
  17. jdrocks

    jdrocks Gravel Runner

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    i suppose there are many different ways to get to the same end, but i look at the wheel center first, then sprocket alignment. the dimension from the outside face of the OEM spacer to the face of the OEM sprocket is known. the thickness of the sprocket is known. when you do the math on the assembly dimension string, you're left with the sprocket spacers on your centered wheel.

    either way, if you now know you're 9mm off center with the wheel, you know precisely what the axle and sprocket spacers should be.
  18. jdrocks

    jdrocks Gravel Runner

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    the leads from the control switches are shorter on the 650R than the Versys, mainly because of the high OEM bar riser. the 650R leads will obviously work since i've been using them, but i thought i would buy some Versys switches if i could find some. the longer leads aren't stressed when the bars are turned to the stops. awhile back i found a set and had them on the shelf ready to go...or so i thought.

    the Versys light switch set has that extra button and the corresponding wires and pins in the connector. no problem plugging into the harness, there are no wires on that side. then i noticed that the plastic locator pin had been cut off the rear housing cover. i pulled the cover off the start/stop set, and that pin had been cut off also.

    get the picture? some dumbass had installed aftermarket bars and just didn't feel like drilling the holes that day. worse, the seller knew it, and still sold them. could really piss ya off, fortunately i had payed very little.

    [​IMG]

    i had some junk in the parts box and came up with covers with the locator pins since i still wanted the long leads. the Versys light switch set has that extra passing switch and now i didn't have a cover to fit that switch. heck, just cut that thing out of there. shrink wrapped the ends, set to go now.

    [​IMG]
  19. jdrocks

    jdrocks Gravel Runner

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    the parts bike was pretty well covered with chalky dust and dirt when i got it. everything was detailed before it was installed in the Versys frame. now it looks like new. all electrical connections greased during assembly.

    used radiator and fan cleaned up and installed.

    just about ready to turn the key.

    [​IMG]
  20. johnwesley

    johnwesley wanta be

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    :clap need to see it with tank and seat