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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    your english is fine, everyone can understand what you're saying, no apology necessary. just get your photo hosting set up and your can directly include your photos.

    i think you should be thinking about a cush hub rear wheel setup. there is an aftermarket DRZ400 cush hub available, and also on the Japan spec DRZ model...or else just adapt a different wheel like the DR650 rear.

    what is your cost in Quebec (USD) to machine the 52mm to 49mm adapters for the lower Versys fork clamp? these...

    [​IMG]

    mine were machined with a self trimming/self positioning flange on top and slotted at the clamp pinch location to assure concentric clamping. were yours done the same way?

    [​IMG]

    i've been asked several times, including recently, about the front 20mm axel, it requires an odd length when using the DRZ400 forks. rather than search the world for a manufactured axel, i used the high tensile 20mm swingarm bolt from the Versys/Ninja and threaded it to the correct length, then cut it off. easy and cheap. it still needs a sleeve for the right side, but you can find one of those.

    [​IMG]

    post those zebra KLR photos in "thumpers", that will cause a stir. looks like you did a knockoff of the Expedition soft pannier mount.
  2. jdrocks

    jdrocks Gravel Runner

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    yup, anything goes, pick your flavor.

    the ER6 builders need to remember to pick up a set of the longer Versys cables, both throttle and clutch. strangely the ER6 clutch cable is of larger diameter than the Versys cable, helping to explain why the Versys cable has a higher failure rate.

    i've had mine out mid build without brakes too. your resistance fades away when it gets to a certain point, ya just have to get on and try it out.
  3. marguyo

    marguyo Adventurer

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    [​IMG]for shim 49 at 52 mm i use same of your set and made .5 mm shim for up for 2 set i pay 100 $ ,for bolt a made a custom bolt same at drz with 3/4 in more long in center and oposit at the tread 3/4 in more long too


    for put many pict tonight i open and accompt in photo bucket and put all picture of my parts

    after diner a go to a small run ,the temp out side is little bit cool 2 deg celsius only and snow falling too
  4. donny662

    donny662 Been here awhile

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    A cush hub alternative would be a sprocket from Kush Sprockets. I've never used a Kush sprocket, but it looks like a neat alternative.

    https://kushsprockets.3dcartstores.com/Suzuki-Kush-Sprocket_p_67.html
  5. S.t.t.G.

    S.t.t.G. Mind over metal...

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    Heavy duty zip/cable ties.....and that's as far as I am going to on this "loaded" topic.:lol3
  6. jdrocks

    jdrocks Gravel Runner

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    not a bad price. did you make the .5mm shim or the machinist?

    yes, bring the photos...keep the snow.
  7. jdrocks

    jdrocks Gravel Runner

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    once again, an alert rider steps up. i forgot about those, but knowing how the bike will get ridden off the pavement, i still make the strong recommendation for a conventional cush hub. applying the WFO HP to the rear wheel is just too common on those roads, especially since you have enough HP/torque to lighten the front end and skip across potholes and washboard.
  8. jdrocks

    jdrocks Gravel Runner

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    the last time i read a description of the zip tie method, the guy started out by saying "first, i got my girlfriend to sit on the bike...".

    whoa there son, stop right there, i don't want any women in my shop that are big enough to compress a 16kg shock spring just from sitting on the bike.

    it was that factor, plus his use of 40 zip ties. if i remember right, nobody got killed.
  9. jdrocks

    jdrocks Gravel Runner

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    Mario fabbed the wheel adapters and fender brackets for this clean stock suspended Versys. i'm not sure which hubs where used for this 17/19 setup, could be KTM. many of the KTM hubs use 20mm bearings, ideal for the 20mm Versys axels.

    [​IMG]
  10. marguyo

    marguyo Adventurer

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    [​IMG]http://s1254.photobucket.com/albums/hh612/marguyo/?action=view&current=DSCF2924.jpg


    my shim for fork

    http://s1254.photobucket.com/albums...612/marguyo/?action=view&current=DSCF2923.jpg

    lower bolt is stock bolt of versys
    middle bolt is stock bolt of drz
    upper bolt is my bolt of my versys adventure



    http://s1254.photobucket.com/albums/hh612/marguyo/?action=view&current=superversyenduroooooo006.jpg


    kit with 21 /17 in wheel stock fork


    sorry for pict ....adv rider system for put picture in post and my is not good ,,,

    1
  11. marguyo

    marguyo Adventurer

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    ist made with solo parts rim +heart of wheel, made all adaptor and put on bike this set up is 21 front and 17 rear
  12. jdrocks

    jdrocks Gravel Runner

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    Mario, direct view photos from your photobucket. from the lower right under "links", select "IMG code", then paste into your ADV post. use "preview post" to make sure it's what you want.

    takes some talent and the right equipment to safely machine the .5mm shim. $100USD is indeed a good price for two complete sets of these custom parts.

    [​IMG]

    good job on the custom axle (top).

    [​IMG]
  13. marguyo

    marguyo Adventurer

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    [​IMG]

    lh side

    [​IMG]

    rh side


    ha la la!!!!!! i am a good student and a good teacher
  14. marguyo

    marguyo Adventurer

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    [​IMG]

    front breake adaptor


    rear sproket adaptor

    [​IMG]

    front break adaptor use not same bolt to fixe adaptor to wheel and fix disk to adaptor[​IMG]


    [​IMG]
  15. marguyo

    marguyo Adventurer

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    my klr ....same part are home made too ...

    [​IMG]
  16. marguyo

    marguyo Adventurer

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    i probably sold and front adaptor kit ,spacer +bolt for fit a drz wheel on drz fork on versys,,this kit not include shim for fit fork and bolt if you want a sheet with spec for made a same of my bolt is possible

    price are ??? i check am confirm this week
  17. jdrocks

    jdrocks Gravel Runner

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    i'd like to see seperate prices for the DRZ400 forks to Versys clamps sleeves/shims, the DRZ front hub adapters/axle, and a set of adapters for a cush hub rear wheel with 20mm axle like the DR650.
  18. Ridin'nFishin

    Ridin'nFishin Real Rider

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    +1
  19. marguyo

    marguyo Adventurer

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    [​IMG]
    [​IMG]
    [​IMG]

    3 parts on kit ,adaptor for disk breake,metric bolt long to fixe adaptor on wheel short bolt to fixe disk on adaptor,

    short spacer to put on bolt at lh side after stock drz shim shim

    am not shim to fit drz fork on versys clam lower and upper

    for bolt i put diameter and wide to made one ,its not on kit
  20. jdrocks

    jdrocks Gravel Runner

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    i wore out the TKC i brought back from the Yukon, so i dusted off the Kenda Big Block i ran for awhile last year and remounted that tire. the Big Block looked like it had some promise as a blocky tread DS tire when it was introduced, but the tire just will not get the miles that you can with the TKC, at least 1500 less for the rear on the V649. the tire is a decent performer, and has about the stiffest tire casing of any bike tire i've encountered, they just wear quickly.

    [​IMG]