BergDonk's DR650s

Discussion in 'Thumpers' started by BergDonk, Dec 20, 2010.

  1. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
    Nov 15, 2010
    Oddometer:
    16,168
    Location:
    Snowy Mountains Oz
    Excellent!
  2. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
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    Oddometer:
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    Location:
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    On my last ride, just before pulling the bike down to get the bracketry plated, the bike developed a bit of a rattle, and the fuel tank seemed to be moving about a bit, especially when full.

    I found the aluminum bracket that connects the two tank 'wings' together and centres on the frame broken.

    I decided to make a new one out of steel. Better now than in the Simpson. Pity the plating is finished, so I guess I'll just paint it for the time being.

    [​IMG]

    I collect all the racks and bits tomorrow from the zinc platers.

    Steve
  3. rowdy_im

    rowdy_im You only die once ,so make the most of living..

    Joined:
    Apr 21, 2007
    Oddometer:
    423
    Location:
    Jindabyne Australia
    Will do the same with mine,welds have almost worn through

    Rowdy:1drink
  4. ep!c

    ep!c Pannier Manufacturer

    Joined:
    Apr 27, 2008
    Oddometer:
    210
    Location:
    Mount Vernon Washington
    Same thing happened to my stock aluminum brace, so I built a new one out of 3/4" square stock. I went a step further and incorporated my useless passenger pegs into the design; by turning them into folding highway pegs that are now attached to the ends of the new brace.....Kind of nice to be able to change up my seating position on longer freeway stretches...
  5. BergDonk

    BergDonk Old Enough to Know Better

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    So perhaps we have a chronic problem with Safari tanks too? Not sure I could get my feet up that high if I had pegs there though, but I do have the option of moving my feet up to the bash plate.

    Steve
  6. ep!c

    ep!c Pannier Manufacturer

    Joined:
    Apr 27, 2008
    Oddometer:
    210
    Location:
    Mount Vernon Washington
    Yeah, the stock part is pretty weak. Maybe it's designed to flex and "give" in the event of a crash?? not sure, but I do like the tank. 7+ gal. on a DRZ is kind of overkill though:wink:. For off-road riding, I usually only put a couple of gallons in it. Kind of nice to have the fuel down low near the engine, so as to gain a lower center of gravity....
  7. AdventureXR650

    AdventureXR650 Esquire

    Joined:
    Sep 1, 2007
    Oddometer:
    157
    Location:
    Yass NSW Oz-trail-ya
    Blokes

    Got a box of bits for the might XR and pulled of the top triple no worries. Fitting the new stuff is a bit different though. The spigot for the stabiliser goes FORWARD to the place where the speedo would be AND is 20mm lower than now. Raising hangers is not as simple as a Ballards bit as the spigot length is set and reversing the spigot (pointing back to tank) is a lot of filing, the oil filler cap won't fit and it will probably hit on the tank.

    Not happy Jan! :cry

    Need some beer to do some brainstorming :1drink
  8. rowdy_im

    rowdy_im You only die once ,so make the most of living..

    Joined:
    Apr 21, 2007
    Oddometer:
    423
    Location:
    Jindabyne Australia
    Bring it down to Jindy a nite in the shed will fix it

    just spent 5 hours putting the orange girl back to gether

    Rowdy:1drink
  9. BergDonk

    BergDonk Old Enough to Know Better

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    I doubt its designed to flex. What I also noticed that with it broken, the tank spread a bit and is not fully supported on the stock frame top tube rubbers. I suspect that more riding with it broken could be a real problem. Should be fixed now though.

    A mate recently purchased a new DR and Safari tank for it and I sent him the pics. He said that his bracket is completely different to the one I had, so maybe its sorted now?

    And the size is still a bit small. For the Simpson we need 600 km range in sand. Its 600 km now, but not in sand. But you're right, you don't have to fill it, and its then arguably better positioned on the bike than in the stock tank.

    And I found my VSM chain catcher has broken too. I'm trying to decide whether to repair it, or do what i should have done in the first place, and make my own. I'll post a pic later.

    Still, this was the idea, get a bullet proof bike, and set it up for a big trip, and test everything before I go so I know what works and doesn't. Hopefully no more surprises :D

    Steve
  10. BergDonk

    BergDonk Old Enough to Know Better

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    I got a new angle grinder the other day if you want a lend. You can pick it up on the way through if you like :freaky
  11. Bushmechanic

    Bushmechanic Adventurer

    Joined:
    Apr 1, 2010
    Oddometer:
    74
    Awesome Steve !

    good preemptive strike, I like the tapered ends of the patches lining up with the shock mount
  12. BergDonk

    BergDonk Old Enough to Know Better

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    It will not break where Snowy has broken it :wink:

    Yeah, not only have I got to test the DR to destruction before the off, but I'm setting up 2 support 4wds with long range tanks, water tanks, suspension, awnings, CBs etc etc.

    Gotta go out to the shed now and buld a new chain catcher.

    Steve
  13. ep!c

    ep!c Pannier Manufacturer

    Joined:
    Apr 27, 2008
    Oddometer:
    210
    Location:
    Mount Vernon Washington
    One thing I've learned to love/hate......There will ALWAYS be more surprises:evil Have a good trip and ride safe!
  14. nolana

    nolana what's that skip?

    Joined:
    Jul 22, 2007
    Oddometer:
    8
    Location:
    Snowy Mountains NSW
    A mate recently purchased a new DR and Safari tank for it and I sent him the pics. He said that his bracket is completely different to the one I had, so maybe its sorted now?


    Rewa's one broke in exact same spot after dalhousie somewhere and we got in touch with aqualine once in alice. Defo a prob with orig design. He sent the new part to alice for us foc (which was great) and we had no probs with the new one for the remaining 3-4000 km that we had the bike. Can't remember the exact difference to be honest, but I'm sure your will be strong.
  15. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
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    Chaincatcher.

    I always use a clip master link on my dirt bike drive chains and have never had a problem. Nevertheless, I like the idea of a sold chaincatcher to reduce the chance of a broken case if something goes wrong.

    I got a VSM catcher sprocket cover http://www.vincestrangmotorcycles.com.au/case_saver.html

    Unfortunately the top monting tang has broken off. Its 4 mm aluminum sheet with a sharp crease so a stress induced fatigue failure perhaps. There is a lso a witnes mark on the underside from the chain contacting it which wouldn't have help. Probably related to the top chain rollers coming out. I did lose mine so when reinstating it, raised it a couple of mm, so this probably didn't help either.

    There is not a lot of space in front of the sprocket with a 16t c/s sprocket, and the VSM unit handles a 16t. Having decided on a 15t, I had a bit more room to play with.

    I cut up a bit of 10 mm plate to suit. Its spaced 4mm from the cases and centres on the chain. The cover plate is spaced 11 mm from the 10 mm plate.

    I used a hole saw to shape the inner circle, and a aluminium cut off disc in an angle grinder to trim the outside. The 4 mm spacers are captive, ie some sheet screwed to the inside, and the cover is 4 mm sheet spaced off the plate that's been drilled and tapped for 6 mm bolts. Spacers were a bit of tube I had lying about, pared off in the lathe. All scrap I had in the shed.

    I used the original as a template, and because its flat, its pretty straightforward.

    Hopefully this sorts it.

    [​IMG]

    [​IMG]

    Now to fit the upgraded swingarm. Notice its being cleaned too :evil

    Steve
  16. BergDonk

    BergDonk Old Enough to Know Better

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    Got the racks and other bits and pieces I've fabricated from steel zinc plated and fitted back up. Also got the upgraded swingarm fitted too. Any takers for the standard one?

    [​IMG]
    [​IMG]

    Steve
  17. rowdy_im

    rowdy_im You only die once ,so make the most of living..

    Joined:
    Apr 21, 2007
    Oddometer:
    423
    Location:
    Jindabyne Australia
    Looks all nice there Berg Donk, wish i had the time to tinker like you

    I am getting there sub frame and rear suspension all overhauled and refitted ,just need to make that safari tank bracket and change the oil ,fit pannier racks and the bashplate /water tank

    then double check all equipment to take

    cheers
    Rowdy:1drink
  18. BergDonk

    BergDonk Old Enough to Know Better

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    Oddometer:
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    Location:
    Snowy Mountains Oz
    Not the best picture, but here is the LED driving lights.

    [​IMG]

    They came from ebay and are 1500 lumens and 30w each, 3 x 500 lumens LEDs each. $150 for the pair. When I initially looked I interpreted the specs as 30 w total, not each, wrong.

    I did a test and found that with high beam and the grips on low it was OK but with the grips on high I dropped 0.3 v. Not terminal, but not ideal. Bump starting in the desert isn't first choice.

    Back to ebay and a 35 w HID H4 conversion for $60 delivered and a LED tailight bulb and I've saved 25 w or so and its all good.

    From what I can figure out, a stock 60/55 w H4 puts out about 800-1000 lumens and the 35 w HID over 3000. Whatever, its all a substantial upgrade in light, and although the LEDs pattern isn't wonderful, its heaps better than none at all and takes a lot of the guesswork out of riding at night. Recommended.

    Steve
  19. BergDonk

    BergDonk Old Enough to Know Better

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    You do have the time to tinker, its just a matter of priorities :D

    I fitted up a new E07 and 606 which should get me to Alice. The previous MT21 E07 combo got almost 7,000 kms and there was probably 1,000 left, but it was raining today... The previous rear E07 had a cut in it which resulted in a puncture on the way to Wallerawang a few weeks ago. We patched the inside and put a fresh tube in, and it got me another 1,000 kms and home, but the cut concerned me, it had a small rock wedged in it when I took it off, so cut my losses and swapped it out.

    Steve
  20. BergDonk

    BergDonk Old Enough to Know Better

    Joined:
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    Oddometer:
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    Got out on the DR on Sat for a run out to check out the local AMCROSS round. Having not been on it for a month while it was apart and busy with other stuff, it was great to get out for a few hours. Disappointingly, it was running poorly at very light throttle openings and was cranky starting for some reason. It felt like it was running lean off the pilot, and adjusting the fuel screw made negligible difference. Confused!

    When home I then remembered I'd made an airbox mod. The standard DR air box mod for stock and pumper carbs is to remove the snorkel and cut out the top to improve air flow. Some have reported fuel economy issues doing this, but after jetting it was fine, with over 500 kms before hitting reserve and another 150 kms or so on reserve.

    The air box mod I'd done was to put a deflector on top to direct air to the back of the airbox and away from the top of the filter which cops most of the flow judging by the grot it accumulates. The deflector made a small reduction in the opening area at the top, and attached simply with a self tapping screw.

    Realising that this was the only change done weeks before and as yet untested, and forgotten about, I removed it, and it was all good again. It amazed me that it only appeared to effect low speed running, a barely open throttle. Once on the needle and the main it was fine. Somehow it was stalling the very low air flows, very interesting :wink:

    The other issue I've been trying to sort is fuel hose routing. The Safari tank sits low on the bike and when going to reserve its still wouldn't go. What was happening was an airloock in the fuel filter and not enough head from the tank to get it flowing again. Hopefully the fix is now a vertically mounted filter below the carb such that the air is purged on main and its still got fuel in it when reserve is needed. Testing yesterday suggests it might be fixed now too.

    Water carriers for the passenger pegs next.

    Steve