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DisTech's DR650 rebuild

Discussion in 'Thumpers' started by DisTech, Dec 13, 2008.

  1. inire

    inire Browncoat symp

    Joined:
    May 9, 2005
    Oddometer:
    412
    Location:
    Javelinas eat my plants
    Cheers!
  2. Ot tuda

    Ot tuda Adventurer

    Joined:
    Sep 14, 2010
    Oddometer:
    24
    Location:
    Nuked joyzi
    just found this thread. OAUUUUUUUUUUUUUUUU. Excelent information.
    I ride 2008 V-strom (20K miles in 2 years).
    My friend lent me his 1998 DR650 for a weekend.

    So, I went upstate NY and bought 1999 DR. I took for nice ride, 200 miles to get home.
    When I started stripping it I found out it was in wors shape then I thought (it was preowned by a 20 something beer guzling guy).
    But I am a hands on mechanical engineer. I have designed, built and installed a couple of machines in the last 30 years of experience.
    I am planing on doing everything my self.

    THANK YOU VERY MUCH FOR THIS THREAD!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
  3. MeterPig

    MeterPig Meh

    Joined:
    Jul 5, 2007
    Oddometer:
    19,014
    Location:
    Parker, Colorado...
    Nice find there. Good thread. I just sold my stock 96. Very cool paint job. I am not a fan of the black as much as the purple.

  4. Rusty Rocket

    Rusty Rocket Life behind "Bars"

    Joined:
    Dec 22, 2005
    Oddometer:
    16,892
    Location:
    Tri- Cities TN
    good to see this thread alive again. I use it as a reference for many things.
  5. Mambo Dave

    Mambo Dave I cannot abide.

    Joined:
    Oct 7, 2011
    Oddometer:
    20,712
    Location:
    11 ft. AMSL
    Hell, then, I'll bump it - even if only just to remind myself that I want to try to build a dash and lighting structure like that.
  6. adventurebound9517

    adventurebound9517 Long timer

    Joined:
    Mar 28, 2011
    Oddometer:
    1,069
    Location:
    Lake Havasu City, AZ.
  7. VtStom

    VtStom Adventurer

    Joined:
    Feb 19, 2010
    Oddometer:
    54
    Location:
    Vermont; where.Happily the roads arent straight!!!
    Yes, I saw one yesterday while at work in Middlebury Vt. It was on a 2006 DR650 that the owner rode down from Montreal Thursday ( A hard core rider if I ever saw one :wink: ) It looked a lot bigger in person than on the website and the Color he had painted it was only slightly lighter than the OEM Blue..
    But the Headlights Look like they could burn thru walls... :poser
    WOW! $800.00 + too steep for my blood...
  8. RedsTitaniumLeg

    RedsTitaniumLeg n00b

    Joined:
    Dec 30, 2014
    Oddometer:
    3
    Replying so I can find it later in tapatalk
  9. SBG

    SBG Neville1 to TT boys

    Joined:
    May 28, 2004
    Oddometer:
    374
    Location:
    Rehoboth MA
    Being a designer, I can't imagine how someone designing a fairing with an adjustable windscreen wouldn't make the screen actually be hidden by the plastic/composite fairing when offroading. The fairing you can cover with background vinyl, but I think if the screen tucked in behind the fairing and then you could slide it up for road riding, it makes a lot more sense. Either that or come up with clear screen protection so a $100+ component isn't getting bush whacked.
  10. Proveick

    Proveick Long timer

    Joined:
    Oct 18, 2013
    Oddometer:
    4,326
    Location:
    CO
    Could someone tell me what the components are to either one of these? Bit confused. Thanks
    [​IMG]

    Guessing a 1/2 " x 1 1/2" bolt
    Nut for 20 mm bolt
    2 1/2" nuts, one with nylon insert?

    Or

    [​IMG]
  11. joenuclear

    joenuclear Still here....

    Joined:
    Mar 16, 2007
    Oddometer:
    10,233
    Location:
    Fort Smith, Arkansas
    ^
  12. joenuclear

    joenuclear Still here....

    Joined:
    Mar 16, 2007
    Oddometer:
    10,233
    Location:
    Fort Smith, Arkansas
    ^
  13. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Going to do the wabdr in July. Time for some updates.

    [​IMG]

    [​IMG]

    [​IMG]

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    [​IMG]
    Tadpole, boboneleg and Rusty Rocket like this.
  14. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Making two brackets, Hope at least one turns out good. So far so good...

    [​IMG]
  15. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    One bracket turned out ugly, but solid and still aligns perfect with the HDB Rallye Lite kit.

    [​IMG]

    When I mount and paint it, it will look alright.

    [​IMG]
  16. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Mouted!

    [​IMG]

    Visualize forks and controls.

    [​IMG]

    It's coming along. Need to do some grinding, paint, electrical, gps mounts.
    boboneleg likes this.
  17. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    First coat.

    [​IMG]
  18. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Last trip (wabdr, orebdr and part of toi loop), the wrist pin clip on my 790 piston came out due to my own stupidity. Ordered a replacement piston, threw it back together and hauled ass across the state to catch my friends that had to keep going on the trip. I missed orebdr and caught up in Idaho. The second piston and rings had the opposite of a proper breakin and the bike has smoked since.

    This posted photo is a little low res, but you can kind of see the wrist pin damage.
    [​IMG]

    Had the cylinder honed, got new rings and spent time making sure the wrist pin clip was properly seated!

    This is what the actual Kramm-Lox clip install tools look like
    [​IMG]

    and here is MrCuervoRacing using installing a clip with it


    I made one.
    [​IMG]
    [​IMG]
    Rusty Rocket and boboneleg like this.
  19. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Been dreaming about the benefits of having a multi axis mill for a long time, but space and money have always been a problem. 3d printers are another route to custom fab. Then I saw the Anet A8 for $160...
    [​IMG]
    [​IMG]

    BEWARE: 3d printers are like a Linux box, yea it's "free", but how much time do you have?
  20. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Early thin wall PLA prototypes.
    [​IMG]
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    plugeye likes this.