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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    i continue to get many inquiries, primarily from Versys riders, about swapping in the DRZ400 49mm conventionals. the fork swap is easy, the wheel and brake setup also fairly easy, with the variables mainly revolving around wheel selection.

    the photo of the 52mm to 49mm sleeves required to reduce the ID of the Versys lower clamp is way back in the thread, so here it is again. the sleeves are upside down in the photo, but you can see that a lip was left on the top so that the sleeve self aligns and self trims when placed in the clamp.

    [​IMG]

    the sleeves are slotted top to bottom, with the slot aligned with the pinch slot on the clamp to achieve concentric clamping pressure, very important. the sleeves were set in the clamps with a few drops of Loctite cylinder sleeve locker.

    [​IMG]

    the upper clamp was reduced from 50mm to 49mm with roll formed sheetmetal of the appropriate gauge and cut to size, only takes a few minutes, and was not glued in place.
  2. MTrider16

    MTrider16 Ridin' in MT

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    Well I'm back home, another 2500 miles on the F8. After following all those moto's around, I'm going to take back my harsh words about the Ohlins suspenders. I think they kept the ride as soft as could be expected, and kept the pig pointed in the right direction most of the time. I didn't think I'd make it a couple times.

    David
  3. jdrocks

    jdrocks Gravel Runner

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    i thought that was the gripe against the OEM forks...too soft.
  4. MTrider16

    MTrider16 Ridin' in MT

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    Sounds about right. I didn't feel them bottom, but yet it soaked up some pretty rough stuff. Centerstand hit a couple of times on g-outs.

    David
  5. kajj

    kajj Been here awhile

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    Hey JD. Do you any close up pic`s on how the versys caliper bolts to the adapter and DRZ fork?
  6. jdrocks

    jdrocks Gravel Runner

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    [​IMG]

    spacer is nominal 1/4", 6.3mm steel. layout, then drill and tap as necessary for full pad contact on the rotor. spacer mounting bolts may need to be clearanced to avoid interference with the rotor.
  7. jdrocks

    jdrocks Gravel Runner

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    at least they're adjustable now. too soft, and the front end wants to dive into Montana trouble before ya can get on the gas to yank it back out.
  8. MTrider16

    MTrider16 Ridin' in MT

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    I'll keep that in mind. :wink: My lack of suspension knowledge is now out for everyone to see.

    David
  9. kajj

    kajj Been here awhile

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    Ok. Thanks.

    I did manage to find a used swingarm bolt from a ER6 to use as the front wheel axle.:clap

    The build will continue in a few weeks when it gets to cold to ride.
  10. jdrocks

    jdrocks Gravel Runner

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    lucky for you, it's a very small world in here. you're safe.
  11. jdrocks

    jdrocks Gravel Runner

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    that's the easiest and least expensive solution. cheaper than buying a bolt or turning a custom axle. it's a true 20mm, no slop on the bearings.

    i thought you guys mounted studded tires and rode all winter.
  12. kajj

    kajj Been here awhile

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    hehe. When will I have time to work on the bike then. I guess it would work for a while.
    But when the temperature drops down below -30 degrees Celsius in mid January It`s a bit to cold to ride.

    I would be fun thou.
  13. jdrocks

    jdrocks Gravel Runner

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    i was riding at Michaux yesterday, just scouting the gravel since i hadn't been there before.

    stopped for fuel on the way back, and a twenty something guy in a beat to crap Jeep Cherokee leaned out the window...

    "does that bike really have 649 horsepower?"

    "yeah son, it really does."

    "oh, way cool."
  14. kajj

    kajj Been here awhile

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    :lol3
  15. ben2go

    ben2go Moto Flunky

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    Some peoples kids. :lol3
  16. jdrocks

    jdrocks Gravel Runner

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    fixed.
  17. jdrocks

    jdrocks Gravel Runner

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    the rat bike on Pennsylvania gravel yesterday...

    [​IMG]

    these cheap-to-build bikes fit the bill for this kind of riding. crosscountry in four states, then plenty of gravel roads, slab it home at 80mph before the deer come out to play.
  18. ben2go

    ben2go Moto Flunky

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    :clap
  19. p0diabl0

    p0diabl0 Been here awhile

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    No no, they're Vietnamese horses, which are like 1/10th the size of American horses. So really, 65 American HP, at the wheel :deal
  20. jdrocks

    jdrocks Gravel Runner

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    that kid was on dope, couldn't tell pony power from horse power on a bet.

    besides, got the cop motor, so he'd have to go into rehab before i could explain the fine points of that swap.


    speaking of horses, i nearly ended up underneath a pair of 1000 pounders today, report to follow.