V649HP-Kawasaki's new gravel runner

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

  1. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    i'm a ways away from any decision, i'll need a seat, tank, and footrests on there at least.
  2. rsteiger

    rsteiger Bob

    Joined:
    Jul 2, 2011
    Oddometer:
    757
    Location:
    Hotlanta Area
    In many assembly plants things like grease, oil, coolant, etc come are paid from the Plant Budget. The Plant gets so much money per bike/car for items like this.

    What I have seen that happens is the plant will begin to reduce the amount of the grease used on a bike to the minimum engineering specification. Problem is that if you target the minimum then half the bikes you produce will over the Engineering minimum specification (and probably ok) and half would be below the Engineering Minimum (probably not ok). The plant then applies the savings to their plant targets which are used for calculating Manager bonuses.

    So basically the Company's Bonus Structure drives poor decision making.. one of the many reasons Edward Deming was opposed to use bonuses as a method of compensation - if you want to retain people pay them what they are worth to the company and take the bonus issue off the table.
    16VGTIDave, WVhillbilly and ben2go like this.
  3. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    very interesting take on the subject. another aspect is that the dealers know that these bikes are shipped without grease in areas that need grease, but they deliver them to customers anyway. these are price point/entry level bikes, and sold to many riders without much, if any, experience with maintenance issues.
  4. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    radiator and guard mounted...

    [​IMG]

    [​IMG]

    the guards all look the same, but they're all different, including this one. little refinements and slightly different mountings, the radiator on this bike gets some additional protection...eventually.

    i had a Versys radiator fan with the correct 3-point mount, but it didn't feel very smooth. i had a nice clean fan from a 2007 ER6F with a 4-point mount, let's use that one. the mounting brackets are interchangeable if you can get them off, good luck, they're mounted with JIS equivalent phillips head screws set with locker. rather than booger two mounts, i clipped one leg off the 2007 fan and mounted it, no problem. the electrical connections are all the same.
    ben2go likes this.
  5. BigChuck

    BigChuck Been here awhile

    Joined:
    Dec 28, 2014
    Oddometer:
    174
    Location:
    Gloucester, Va
    I have to admit, I had reservations about the white frame before now. I always liked the red frame bike the best, and have thought about copying it on my build now that it is gone ( from the east coast at least ), but the white is starting to really look good.
    It will be interesting to see what other colors you put with it.

    Damn... the more I look at that picture, the more I wish I had thought of it first.
  6. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    yes, interesting. if you go through some of these design studies with the thought in mind that you want the final product to function at some elevated level, yet look darn good doing it, you start to appreciate the time and effort it takes a professional designer to produce a product that is market ready. hit it, you're a freakin' hero, miss it, it costs your job and reputation.

    Charles, regarding your bike build...visualize, my friend. visualization is by far the best tool in the box.

    the white pallette is both an opportunity and a challenge. it makes all other colors pop, choose carefully.
  7. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    it's a pain moving the bike around the shop without a side stand, so i needed to break from the other things i had on the list and fab an extended sidestand. i couldn't do this before the motor was installed, the weight needs to be on the bike, although in this case i had a number in mind that turned out to be correct. the previous bike had a stand extended 90mm, but 85mm works a little better. the stand number confirms that the stance of the bike is very similar to the previous V649 editions even though the 48mm USD forks are new.

    the sidestand used is the 08+ KLR, don't bother trying to lengthen any ER6 sidestand, won't work well. i didn't take any photos of the work yesterday, i was in a hurry, but had some in the archives for those interested.

    the sidestand is marked with a centerline index, then cut at the mid-point below the bend. the sidestand tube ID happens to be exactly the same as the OD of OEM metric bars, and the bar tubing has a decent sidewall thickness making the choice perfect.

    [​IMG]

    [​IMG]

    [​IMG]

    i use 25mm on each end of the extension to insert into the stand. tack the extension to the top section, then install the unfinished stand on the bike. with the bike over concrete, now slip the lower section of the stand onto the extension, land the foot to the concrete with the cut on your length index mark, checking to make sure that everything aligns as planned. mark a new index line for the lower section, remove the stand, and make your welds. the extension is smoothed to the stand with body filler, and should be invisible when finished.

    [​IMG]

    [​IMG]
    Nick MN likes this.
  8. Eddy Alvarez

    Eddy Alvarez Long timer

    Joined:
    Oct 21, 2008
    Oddometer:
    3,206
    Location:
    Chester,VA
    Cool, I didn't know a replacement was already in the works! Subscribed...:lurk
  9. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    Eddy, you're already fast, but i'd sure like to see what a young man could do with one of these.

    the buyer of the V649 red frame is a trials rider, i'd expect him to take that bike some places i might not.
  10. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    2,151
    Location:
    Mid Wet Or A Gun
    I like your white paint.
    I work with / build bench top and larger test equipment and often have to work / build with aluminum parts that have been black anodized.
    Looks cool but it zaps light like a black hole. What a PITA !
    Ya need a flash light to see to build.
    Now take clear or hard anodizing over aluminum, and I am in heaven.
    Rally car guys sometimes paint their engine compartment white.
    Shine a light in there and the whole compartment lights up.
    hughrk likes this.
  11. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    thanks, so far so good. might get it a little dirty.

    when i drop anything on these bikes, it always ends up under the throttle bodies down by the starter. takes some doing fishing it out of the coal colored engine.
  12. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    got an inquiry on the custom extended side stand..."I get how you measure the required length, index the cuts, index the final alignment, I can weld it just fine, and I can fill it with body putty. I don't get how you make it so smooth and straight without a lot of work."

    i should have included the answer earlier, but forgot to mention it. dressing the bondo is done with a half sheet of sanding paper, 8 1/2 by 5 1/2, or let's say 140mm wide...ring a bell. the extension is only 85mm long so the half sheet rides on the original side stand tubing on both sides. when pulled tight during the smoothing operation, the paper is perfectly straight and since it's riding on the tubing, the new surface has exactly the same radius as the original. start with 80, finish with 220. perfection in about 10 minutes, ready to prime.

    [​IMG]

    [​IMG]
    JagLite likes this.
  13. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    the beastly EX650 swingarm conveniently comes with an OEM hugger, and it really does help...

    [​IMG]
    JagLite and scot_douglas like this.
  14. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    2,151
    Location:
    Mid Wet Or A Gun
    Talking about having the dropies, my bud and I were having too much fun jaber jawing while doing a valve adjust on my 950 KTM ADV.
    Shims that look like slices of pencil erasers.
    Sure e-nuf one got away and into the bowels of the engine...................Our minds race ahead in lost time that we will never get back.
    What if we turn the bike upside down? We got to split the cases. Might as well do a complete rebuild. All kinds of thoughts flashed before both of us in nano second time. I still remember the look on his face! I know I had the same look, but we both kept cool heads and wore big shit eating grins. Where's your magnet on a stick he said and I grabbed it out of my tool box. He went fishing blind. We both heard a small click and dang if he did not find it sitting on a ledge still on the top end but down 6 inchs out of sight into the black abis. WOOT ! Good times indeed...comes from living right...
    Looks like your getting you gravel runners down to a science...good on ya JD.
  15. ben2go

    ben2go Moto Flunky

    Joined:
    Jun 23, 2011
    Oddometer:
    5,618
    Location:
    Upstate SC USA
    Gotta stuff your jock sock down in there to keep them from making their way into the engine.
  16. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    ^^^^^i don't like hearing strange sounds when i drop something, it usually indicates how i'm going to spend the next hour. of course, sometimes the dropped object doesn't turn up for a month or two, sometimes never.
  17. Hatori

    Hatori Adventurer

    Joined:
    Oct 4, 2016
    Oddometer:
    62
    Location:
    ADVRider
    JagLite likes this.
  18. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    sorry, i was thinking in terms of hot-rodding the whole bike, not swapping the motor. i took a quick look at that thread and the first thought that came to mind was of all the places that the builders of the Versys/Ninja hot rods have taken their bikes, and the absolute pounding the bikes took to get in there and back out. i like the concept, hope it works out, he's chosen the long way 'round.

    @tonymorr, the same inmate who is the grand-daddy of the ER6 builds, had an FZ07 that he ruggedized a little, but it wasn't a full blown build. looks cool, since sold.
    [​IMG]
  19. Hatori

    Hatori Adventurer

    Joined:
    Oct 4, 2016
    Oddometer:
    62
    Location:
    ADVRider
    I think he is definitely willing to throw money at it to get it exactly how he wants it. Guess other than the option you have chosen there is no other way. As you once said;
    Just a shame mfgs don't make powerful, light twin adv bikes off the showroom floor!
  20. jdrocks

    jdrocks Gravel Runner

    Joined:
    Jul 6, 2007
    Oddometer:
    6,415
    i'm the opposite side of that coin...build a bike exactly how you want it without throwing hardly any money at it.

    there are two of these big suspension V649 style bikes underway here in eastern Virginia that will turnkey at $1000 or less, maybe a lot less depending, each with fresh low mile cop motor power. crazy cheap money for a moto that checks off lots of boxes.
    JagLite, Hatori and nickguzzi like this.