DisTech's DR790 build

Discussion in 'Thumpers' started by DisTech, Mar 16, 2013.

  1. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Thanks EBMOTT.

    Reassemble progress! Let's see what we have here.
    1. 790cc motor
    2. Swingarm with new bearings
    3. Rear wheel with Excel 18, D606 and new bearings
    4. RMZ450 triple with new head tube bearings
    5. RMZ450 forks with new RaceTech .52 springs, seals and wipers
    6. nav tower mount
    7. stabilizer post
    [​IMG]
    #41
  2. PhiSig1071

    PhiSig1071 What's ******width?

    Joined:
    Apr 9, 2008
    Oddometer:
    2,763
    Location:
    Tucson, AZ
    Looks awesome!

    Excuse what may be a dumb question, why the switch in wheel width? And is 4.25 the stock width? That sounds closer to a SM tire.
    #42
  3. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Thanks. I'm going for the kick ass, low maintenance dual sport that runs good on crappy gas and has easy to source consumables (21 tires and 520 chain & sprockets). I looked at 18x4.25's (KTM 950/990's use them) but I wanted an Excel rim and the price jump over 2.5 width is big and over 3.5 is ridiculous.
    #43
  4. GRinCR

    GRinCR Oppressed Nomad

    Joined:
    Apr 29, 2011
    Oddometer:
    616
    Location:
    Alajuela, Costa Rica via MN.
    :nod :tb :lurk
    #44
  5. zilla

    zilla Long timer

    Joined:
    Jan 22, 2006
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    1,722
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    People's Republic Of Illinois
    SWEET!!!!!!!!!:clap
    #45
  6. bobfab

    bobfab Long timer Supporter

    Joined:
    May 11, 2009
    Oddometer:
    2,358
    Location:
    Limerick, PA
    me too! Moar!
    #46
  7. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Welcome lurkers!

    More progress and she's a roller!

    1. Front wheel
      • RMZ450 front hub and rotor
      • Excel 21
    2. Exhaust
    3. Rear brakes functional
    4. Front brakes
      • RMZ450 master cylinder
      • DR650 brake line, was longer and beefier than the RMZ one
      • DR650 brake cylinder, identical to the RMZ one but already had Vapor speedo sensor mounting hole
      • Had to order a M6x12.7 magnet rotor bolt from TrailTech because the DR650 one is M8
      • Still need to bleed
    5. BRP Top clamp/sub mount for Scotts stabilizer
    6. HDB Top clamp
    7. Carb cables
    8. General cable, wire and vent routing. It is a puzzle!
    [​IMG]
    #47
  8. Scubawerx

    Scubawerx Scubawerx

    Joined:
    Dec 19, 2012
    Oddometer:
    805
    Location:
    North Georgia
    Keep it coming. This is great stuff.
    #48
  9. plutonic

    plutonic Outsider

    Joined:
    Sep 9, 2006
    Oddometer:
    5,150
    Location:
    Alpharetta, GA-Budapest, Hungary
    :thumbup:lurk
    #49
  10. Northwoods Yeti

    Northwoods Yeti Almost house broken

    Joined:
    May 3, 2006
    Oddometer:
    2,956
    Location:
    West Coast of WI
    Great build!:D
    #50
  11. EBMOTT

    EBMOTT Adventurer

    Joined:
    Jun 28, 2011
    Oddometer:
    70
    Location:
    SANTA ROSA, CA
    looks good ,I was wondering what bend are you running on your pro tapers? could be just photo but they look really tall. keep it up cant wait to see final out come.:lurk
    #51
  12. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Pastrana FMX. I'm 6-5" so with the FMX, BRP top clamp/submount and ProCycle lowered pegs I can finally stand comfortably.
    #52
  13. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    This is good news!
    <iframe width="853" height="480" src="http://www.youtube.com/embed/b1-gvCMQ6ls?rel=0" frameborder="0" allowfullscreen></iframe>

    :clap
    #53
  14. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Organized resistance.
    [​IMG]
    #54
  15. chasbo

    chasbo Long timer Supporter

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    May 8, 2005
    Oddometer:
    3,427
    Location:
    Prescott Valley, Arizona
    Sounds awesome man!

    oooooooo........beer
    #55
  16. EBMOTT

    EBMOTT Adventurer

    Joined:
    Jun 28, 2011
    Oddometer:
    70
    Location:
    SANTA ROSA, CA
    MILLER TIME:dutch
    #56
  17. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    The DRZ400 switch has four connectors and the DR650 has six. From the wiring diagrams you can see that the switches do the same thing (even same wire colors) except the DRZ does not have the O/Y & B/W circuit with the resistor. Here is my 100ohm 1/4watt 5% substitute resistor circuit.
    [​IMG]

    This is the key switch I got from ebay, "New Genuine Suzuki Ignition Switch 2000-2011 DRZ400 S DRZ400SM OEM Keys #F99". I replaced the four connector with a six and put the resistor on the switch side of the coupling. Spade connectors and electrical tape is temporary because I wanted to test the switch but don't know how long the pigtail needs to be yet. The switch worked perfect. :clap
    [​IMG]
    #57
    proeliator likes this.
  18. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Mock-up!
    [​IMG]

    Proceed to fabrication!
    [​IMG]
    #58
  19. Phreaky Phil

    Phreaky Phil Long timer

    Joined:
    Mar 18, 2006
    Oddometer:
    2,950
    Location:
    NEW ZEALAND
    I used the same ignition on my 650 and wired it so when in park position it kept power to my GPS and aux plug. This is great so the GPS stays on and doesnt keep wanting to turn off and our intercom stays on, so if we are sitting on the bike waiting we can talk.
    #59
  20. DisTech

    DisTech Been here awhile Supporter

    Joined:
    Sep 3, 2008
    Oddometer:
    658
    Location:
    Seattle
    Given the lack of tools I have for bending metal, I'm pretty happy with how symmetrical the brackets turned out.
    [​IMG]
    #60