V649HP-Kawasaki's new gravel runner

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

  1. yokesman

    yokesman Been here awhile

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    03-04 636(clipons) both uppr,lower 50mm complete bolton,see ninja 650 forum
    need additional work for bar clamps
    05-08 z1000 uppers only 50mm, single bolt bar clamps-rubber mounted
  2. jdrocks

    jdrocks Gravel Runner

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    i know the 49mm DRZ fork inners fit into the ID of these triples, i'm more interested in a centerline dimension of the clamps for comparison with the OEM Versys clamps. used z1000 clamps are available, but i didn't see anything cheap after a quick look, whereas the 636 clamps are easily found cheap.

    50mm ID clamps just need a rolled formed sheet metal shim rather than a machined adapter for the 49mm fork tubes. easy enough, two sets for maybe $5.

    so, if you have these triples, how about supplying a centerline dimension?


    from his post in that linked thread, the builder clearanced the DRZ/DL setup so that the wheel could be mounted. i'm not sure how that's all going to work out.
  3. yokesman

    yokesman Been here awhile

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    03-04 636 triples approx 8.32 c/c
  4. jdrocks

    jdrocks Gravel Runner

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    thanks, been away from the shop for a few days, i'll try to pull the centers on the Versys clamps in the next day or so.
  5. jdrocks

    jdrocks Gravel Runner

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    ok, checked the dimension of the Versys triples, and found 210mm. i suggest that the 8.32" is really 210mm for the 636 also, since these metric motos rarely have an odd number dimension. as mentioned, the OEM DRZ triples are 20mm narrower, making them 190mm, c/c. would certainly work with a narrow hub spoke wheel, DRZ or other, but not well with the DL cast wheel.

    there is a ton of threads on the 636 fork conversion on the EX650/ER6/650R, with most of the discussion about wheels/bearings/brakes/fender/bodywork. the triples bolt right up to the ER6 series, and would on the Versys framed bikes also since they share the same steering head. some of the 636 triples apparently do not have steering stops on the lower clamp, so stops are tigged in place, easy.

    i don't have a set of 636 triples, but i doubt it would be a big deal to work out the placement of a set of bar risers, or you can actually buy an aftermarket 636 top clamp set up for MX bars, or possibly fit the Z1000 top clamp. plenty of reading on the subject, it all seems pretty easy stuff.


    [​IMG]
  6. yokesman

    yokesman Been here awhile

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    what is the weight of that dl front wheel,i bought a virago front wheel ,it is heavy and pos hashed it up taking the tire off-which was part of the deal.
    Besides that it is a open hub which I donot like for any mud use.
    still looking for that 19 inch wheel.
  7. jdrocks

    jdrocks Gravel Runner

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    don't know exactly, but i'd guess 12-14# for the bare wheel, 28-30# full dress with a DS type tire.

    i'll weigh it the next tire i have it off...if i remember.
  8. yokesman

    yokesman Been here awhile

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    JD
    First I want to thank you for starting this thread,I did have much info logged over the last three years but the computer has take that nap of finality so I want to ask you about the R 1 shock once more,the total length eye to eye and the stroke.
    I finally picked up the bike of choice while waiting for a ninja to surface with all the right numbers. It is a 09 gladius,7600 miles needs a waterpump(only used on the gladius and 12 dl) brake pedal,front brake lever same as the dl)and riders right peg(also shared with the 1400 concourse) ,gas tank (will be replaced with a dl tank.
    the seat came from the wood pile and was covered by design.
    will start some sort of thread once i know what i am doing,besides copying your work on this platform I donot have the parts located as of yet.
    Have some double buckets seatcovers coming ,seahorse cases and hope to have the bag rack support arm design solidified in a day or so,just need to find all the hidden bolt locations under the plastic.
    Lastly as I not determined how effective the R1 shock will be on this bike yet,your input would greatly be appreciated,Richard
  9. OHjim

    OHjim Been here awhile

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    :ear You bought a Suzuki with Kawasaki footpegs and want to know if "Mr Cop Motor Ninja" can help you fit a Yamaha shock? :huh :freaky

    At least fitting the DL650 wheels will be easy . . . . :wink:
  10. jdrocks

    jdrocks Gravel Runner

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    should be a good bike to build, although you don't say how you're going to use it. there have been plenty of fork swaps on the SV, well documented if you want to go that direction.

    the R1 comes in several configurations depending on model year, with most of the differences having to do with the position of the reservoir. the Versys/ER6 builds use the 07/08 version because the reservoir placement doesn't interfere with anything other than a plastic panel, easily trimmed, if used at all.

    the R1 is about 300mm with a stroke of 57.5mm (64mm if bumper compression is included), and comes with an OEM 8.9kg spring...ok for use on the R1 linked suspension, but too soft for the Versys direct coupled setup.

    i can't say whether the shock would be any good for your build.

    start a thread, let's see what you're up to.
  11. yokesman

    yokesman Been here awhile

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    basically a RTW bike-roads of whatever the local populace uses.
    same setuo you have just adjusted to the gladius platform,hoping of course that the info I have from this thread would crossover smoothly-getting into the riding season soon.
    the gladius shock is 330 in length but center mounted so I have to learn how that will change the setup and shock choice.(up to this point I planned to just follow your lead0
    on the sv site found sonic springs,kit for the forks at $80. (up to 1.1 )but no rear springs offered.
  12. jdrocks

    jdrocks Gravel Runner

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    i would if i could, but i haven't had my hands on that particular bike.

    i just like to see guys jump in and build something.



    just back from a 1200 mile ride, lots of gravel road, some only roughly graded. 80 cruise in some hard rain and heavy traffic on the return leg, the rat bike alive with all those freakin' lights blazing away.

    i have to say that it is gratifying to do these rides, sometimes nothing real easy about them...all roads, all conditions, on a moto you put together with your own hands.
  13. MTrider16

    MTrider16 Ridin' in MT

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    :clap Glad to hear one of us is riding. Got snow again today, still isn't really what I would call riding temperatures. Compressor at work messed up the crankshaft due to lack of lube. Industrial version of forgetting to put the drain plug in after the oil change. 6 digits expensive, mechanics, scheduling, overtime, gaah! don't get me started. While the mountains didn't get huge amounts of snow this year, its melting slowly.

    David
  14. jdrocks

    jdrocks Gravel Runner

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    i'd laugh at the stupid stuff men do if there wasn't so much pain and money involved...sometimes risk too. i could tell stories for days on end, and feel fortunate that i never lost a man in my professional career, no thanks to some of them who had the situational awareness of a rutabaga.

    i see those weather fronts coming through out there. Red River flooding again, Missouri high.
  15. yokesman

    yokesman Been here awhile

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    JD as my thoughts are going to dual discs for pad life and road performance
    does it look like using a left leg on the right of the drz setup would be a go.
    thanks again for this thread and the info it contains freely and clearly shared.
  16. jdrocks

    jdrocks Gravel Runner

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    in the context of the way i use the bike, i don't view the double rotor as necessary, or even desirable. i'm using the 310mm DL/SV rotor, braided brake line, and OEM ER6 caliper with OEM pads. the bike stops fine with that combo, with the next upgrade being after market pads, and beyond that, a 4 pot caliper, another easy swap. i have a 4 pot caliper ready to go, but have not bothered yet. coincidentally, i just checked the front pads for wear last week, and they still looked ok after 30,000 miles. i guess i don't use the brakes much...yikes.

    the bike stops well on pavement, but i use controlled two finger braking on gravel all day without concern of locking up the front. factor in other issues like unsprung weight, and additional parts and brake lines subject to damage when that moto is ridden on rough "roads", or inadvertently parked upside down...i'll stay with what i have, at least until i find a good reason to make a change.

    since you would be starting from scratch, you could go large rotor, braided line, 4 pot with upgraded pads. the caliper adapter is easy to fabricate either way.

    changing out the right DRZ fork leg has been discussed, but no one has said they actually did it. we'll need a report/photos if you make the swap.
  17. MTrider16

    MTrider16 Ridin' in MT

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    Sometimes laughter is the only thing keeping me say. I'ffen I live as long as you I will have plenty of stories to tell.

    Yep, the last few fronts have had lots of moisture. Pretty good odds Fargo will flood again. Missouri will get high, not excessive flooding.

    David
  18. jdrocks

    jdrocks Gravel Runner

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    damn, y'all have a long way to go.

    i could write a book about spending my entire adult life training grown men not to do downright stupid stuff. at least i brought 'em all home, and i'm kinda proud of that.
  19. MTrider16

    MTrider16 Ridin' in MT

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    That is something to be proud of. :bow

    David
  20. 4play

    4play Next?

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    JD, I'm nearing completeion (except for paint) and had planned to leave the muffler stock. I just read the stamping on thye muffler & there is no mention of a spark arrestor. With the cat intact, I feel it's safe, but I don't believe it'll be legal on the trails. I have been checked a couple of times on my KTM.
    Thoughts/ideas?