V649HP-Kawasaki's new gravel runner

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

  1. OHjim

    OHjim Been here awhile

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    JD - Do you know what the length (eye to eye) and travel is for the R1 shock? I searched the thread but couldn't find it. Also I know you changed to a 900 lb/in spring but do you know what the OEM rate is?

    Thanks.
  2. jdrocks

    jdrocks Gravel Runner

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    4,580
    the R1 is just slightly longer, maybe 10mm, with about a 7mm longer stroke which yields about 6.5" of travel...except it's not usable since the tire will contact the fender liner first. the tire will hit the liner with the OEM shock too if the shock is bottomed.

    the OEM Versys spring is 16kg/mm or 895#. i replaced it with the 900# custom spring, or 16.1kg/mm.

    i think guys swapping in the R1 tend to use a spring that's a little too light for gravel road use, or any other condition where there might be a load on the bike.
  3. jdrocks

    jdrocks Gravel Runner

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    the thing looks like a pile of goop, but it's the mold for the fiberglass rear fender. did i mention that i hate working with this stuff, but fortunately it doesn't take all that long. it takes longer to figure out what the shape should be than it does to mold the part.

    [​IMG]

    while the resin was setting, i made up the plate mount. left a little room for a LED plate light.

    [​IMG]
  4. MTrider16

    MTrider16 Ridin' in MT

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    lol. I like your stories JD, you do know how to drag them out for effect. :wink:

    David
  5. jdrocks

    jdrocks Gravel Runner

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    i could write a report on my efforts making fiberglass parts, now there's a long rocky road.

    that's nasty stuff to work with, next time i'm going to subcontract the work to this moto guy in Montana, he must be looking for some winter work, tired of forking hay to those cows already.
  6. sanjoh

    sanjoh Purveyor of Light

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    Location:
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    It wouldn't be ADV without it.

    How do you do this:

    Threads: 602,598, Oddometer: 18,488,556, Inmates: 216,968

    and not take advertising:deal
  7. jdrocks

    jdrocks Gravel Runner

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    plus, they let guys sell LED lights and stuff.
  8. jdrocks

    jdrocks Gravel Runner

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    grabbed a little shop time to fab the last little pieces for the tail, a pair of light mounts. the small parts seem to take twice as long to fabricate than anything larger.

    [​IMG]
  9. jdrocks

    jdrocks Gravel Runner

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    then the light mounts get welded on the sides if the plate mount...

    [​IMG]
  10. jdrocks

    jdrocks Gravel Runner

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    4,580
    then a little primer on the new fiberglass rear fender...

    [​IMG]

    nothing like some primer to bring out things that need attention before the topcoat.
  11. jdrocks

    jdrocks Gravel Runner

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    painted a bunch of parts, always a challenge spraying urethane in a cold shop, and started reassembling the tail. i wanted more light on the bike after numerous long runs in the dark this season, surrounded by cager madness.

    the first new lights were LEDs flanking each side of the plate that get tied into the brake light circuit.

    [​IMG]

    the lights are tucked in tight, but visible from the rear and side, and have a wrap around gravel guard for bottom and front protection.

    there's also a new LED strip light above the plate, way brighter than the OEM light.
  12. jdrocks

    jdrocks Gravel Runner

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    the next set of new anti-cager lights are 2" LEDs mounted in behind the Wolfman racks, and between the two will show plenty of red on the back of the bike. these are tied in on the running light circuit.

    [​IMG]

    [​IMG]
  13. MTrider16

    MTrider16 Ridin' in MT

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    Looks good JD, when are you going to bring the horse out from from behind the barn and give us a full on picture?

    How much weight did your horse gain in this procedure?

    David
  14. jdrocks

    jdrocks Gravel Runner

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    not much net gain...unless you factor in urethane paint. i think the parts have around 5# of urethane tar stuck to them.

    i need to wire the tail, and there's another set of lights too. then some other changes, and more paint. i need to hurry up, big expedition planned.
  15. jdrocks

    jdrocks Gravel Runner

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    new 2" amber LEDs mounted behind the Motech guards, out of harms way, also on a running light circuit. i think i'll put the ADVmonster LEDs back on too, help those cagers see me. it may seem extreme to add all these lights, but over this past season of travel, i've had more close calls than i could begin to count.

    [​IMG]

    now, on to the rest of the plan to make the bike more visible.
  16. jdrocks

    jdrocks Gravel Runner

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    i planned on doing a series of changes to the lights as the photos show, but i had one perplexing little problem. my donor bike was an ER6, the rat bike is a Versys and used the Versys tail light. there are only two differences in the wiring harness connectors that i know of, the main instrument connection and the tail light. i used generic uninsulated pin connectors and a little goop to make it this far, but it always bothered me.

    i didn't want to buy the whole harness just for one little piece of it...hmmm, i happened to know of this Texan who was dismantling a Versys for his next ptwin powered KLR build, what are the chances...?

    sent down a PM inquiry, and only a couple days later, this shows up in the mail

    [​IMG]

    thanks again Mr. KLRsys, it was one heck of a favor.
  17. jdrocks

    jdrocks Gravel Runner

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    slooooow progress. every time i completed one thing on the list, i added a couple from the season of deferred maintenance. the poor rat took a beating out there this season, nothing serious.

    new color, that other white had too much brown in it, plus a real red tank. the red i sprayed before wasn't red enough.

    now i need to get the rest of the wiring tied in, bingo, i'm ready for a road trip.

    [​IMG]
  18. jdrocks

    jdrocks Gravel Runner

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    one of the things i wanted to do when i had the front apart was to reinstall the ADVmonster LED lights. i crushed one of the lights up against a tree a while back so i had been running the PIAAs since then. the folks at ADVmonster fixed my light, great customer service, but i hadn't had the chance to stick them back on. i set up both sets of lights with the same connectors and it was just a matter of unplugging one set and installing the other. the lights are on a completely independent circuit from the main lighting, and i had a red pilot light on the dash to indicate "ON", but that light burned out and i replaced it with a new red LED. hope it lasts longer.

    i had forgotten how bright these lights are, way brighter than the PIAA 510s. these lights are the 44s, Sanjoh at ADVmonster may have an even brighter light now.

    [​IMG]

    [​IMG]
  19. MTrider16

    MTrider16 Ridin' in MT

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    Its looking good JD, like the pictures and the upgrades. -David
  20. nononsense4857

    nononsense4857 Adventurer

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    Mar 12, 2012
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    45
    Envy your Buell setup JD. Those dual head lights look beautiful on the bike.
    Spent a LOT of time online to find the assembly for purchase, but i gave up.

    Once i was back from my long trip on the 650, the bike refused to fire up one morning. When i press the ignition switch i can hear the FI pump do the humming and then nothing happens. There was no cranking.

    Finally the problem worked out to be the battery.

    I just run it everyday and clock 10k kilometers in a month and the battery dies?? This scares me now to do any kind of electrical upgrades fearing the same problem might happen over a trip. I was on an almost stock setup - electrical wise... i did not have anything modded except replaced the stock lights to one single 100 w bulb which was switched off during day time running.

    You have two cigarette lighter sockets taking care of your GPS and others stuff which i presume remain ON through out your trip...

    How did you go about this?

    I just ordered the marinco cigarette lighter assembly + some in-line fuses and hope to have power outlets for the electrical pump and another for a communication solution which i have not bought yet.