Dl650 Hack

Discussion in 'Hacks' started by brstar, Dec 26, 2010.

  1. brstar

    brstar Long timer

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    "If you cut a spring you increase the spring rate and decrease maximum travel before coil bind"
    Had to think about that.
    1st thought, how does a cut change anything???
    No its the shorter length that changes things

    "If you stack 2 springs you decrease the spring rate and increase travel"
    You are saying here in effect the spring length varies the rate?
    Not sure about that.

    "If you nest 2 springs you increase the spring rate (add the 2 rates together), travel is limited to whichever one has the least"
    Or the amount of travel available in the forks?
    Triumph springs are soft.
    Yam springs support a similar weight with a lot less travel so most likely a little stiffer.
    So nest them on both legs and get double the carry capacity. ( give or take)
    Nest them on one leg and get a 50% gain.

    I would hate to disappoint Buck.
    OK then random facts and figures.

    Triumph tiger forks (1996).
    Bike weighs 209kg dry so 235kg? wet?
    5mm dia. 45 coils @ 545mm long = 225 solid +320 space so the 215mm (actual) travel fits easy.


    XS650 spring (I have 4).
    Bike weighed 225kg wet. (heavy slug)
    4mm Dia 63 coils @ 393mm long = 252 solid +141 space ( stock Yam had 130mm fork travel according to Clymer)
    Right so then for some creativity.
    If I cut 2 springs down and add them (stack) so as to have one and a half or so then I can utilize 664mm or even 678mm if I go up into the fork caps.
    The Yam springs go right through the Triumph spring spacers giving more length.
    @ 664mm we get 105 coils making 420mm solid spring and 244mm space for travel....ample.

    Trick is to keep the Yam springs from clashing with the Triumph ones.
    More so because they are stacked and the cut will throw them off line a bit.
    If I did I would relieve the 25mm or so of preload, maybe give it 10mm as a token to stop rattle etc.
    So.
    Add springs to 1 leg?
    Add springs to both?
    Buy new maybe not quite heavy enough springs and slap em in?
    Can be done of course but is it worth it?

    [​IMG]

    Ok I need to eat and get back to the Western list (gunnado) while Y'all thunk on it.
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  2. FLYING EYEBALL

    FLYING EYEBALL out of step

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    stock spring rate is about .78kg iirc I ran 1.00 on my solo 650 Strom's and I was running 1.20kg on my Camo Sputnik Rig.

    I'm a big Bloke fwiw.

    Sonics on the solo bought second hand and new Race Techs for the Rig for around 100 (US) foldable Beer Tokens from that online Auction site.
  3. brstar

    brstar Long timer

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    Stock springs on the Wee were always to soft for me at 104KG or there a bouts.
    Can't believe I never upgraded the springs though.
    So that's .78KG/mm?
    Stock Triumph Tiger forks come in at .38KG/mm.
    Soft as.
    Here is the Triumph spacer in the chuck with my new? spacer tube thingy made from an old tent pole and a piece of hole-saw off-cut.
    Needs another cap to go under the fork cap.

    [​IMG]

    Just need to make another short sleeve with 12mm center hole for oil/air flow to stop the Yam spring from moving sideways and also more importantly from dropping down into the lower part of the fork.
    Hopefully nothing comes up into the fork tube on compression?

    [​IMG]
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  4. tomrux

    tomrux Been here awhile

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    "Hopefully nothing comes up into the fork tube on compression?"

    Yep, that would be the damper tube. Going to need some very careful measuring here or this is going to go terribly wrong.

    Cheers
    Tom R
  5. brstar

    brstar Long timer

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    Thanks mmmmaaate for the minor heart stopping moment.

    With the scientific aid of a broom stick I very cunningly discerned the that was not the case in this instance.
    Only had to use spell check 3 times in that sentence.

    [​IMG]
    Should be 25mm or so clearnce on the tube spacers at full compression.
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  6. brstar

    brstar Long timer

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    Turned up in the mail box today.
    Good thing I had other things to do while I waited.
    Originally ordered the second of January.

    [/ATTACH] 20200219_155137.jpg 20200219_164820.jpg
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  7. brstar

    brstar Long timer

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    20200227_092657.jpg
    Was checking out the local steel supplies.
    Saw this arrive back from a delivery.
    Check out the seat.
    No fuel cap either.
    Barbeque anyone?
    This is the long wheelbase version.
    They deliver 6 meter lengths on it.
    20200227_084033.jpg
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  8. brstar

    brstar Long timer

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    Thought I best start with a shot of a 3 wheeler

    [​IMG]
    This one happens to be the family transport in Sen Sok 6 Where I stay these days on what has turned out to be my annual visit to see my daughter and her family.
    Its amazing how quick the technological jump is sometimes.
    What worked last year is no longer main stream viable.
    Passap and the apps to suit on smart phones have all but killed off the older style Tuk Tuks.
    The ones with a 125 step thru as a tug along with a 4 seat trailer.
    Replaced by these with I think around 300cc engine running on LPG.
    They are faster being able to rip along at 50kph easily.
    Even my wife without the local language is able to call up a ride.
    She gets a picture of the vehicle and its driver and a set price for the trip and he can see on his phone where he has to drop her off.
    Both are covered.
    And now there are many more concrete road in Phnom Phen the little wheels manage ok.
    Of course the early starters had a good run for a while till there became a glut of three wheel tuk tuks.
    Hence this one is relegated to home transport and deliveries for their little side business.
    Did a few runs to the kids (4 and 6 yr olds) school then dropped their mum of at work while me and their dad went home to work on the new roof frame.

    [​IMG]

    [​IMG]

    Trip home became a little more of an adventure than I wanted as well.
    We were booked for a night in a hotel near Chiangi airport Singapore as there are no direct flights from Cambodia to Perth.
    A couple of days before our arrival Singapore said all visitors must isolate for 14 days.
    This meant a night trying to sleep on chairs in the airport.
    Still it could have been worse by far.


    [​IMG]

    Cancelled seemed to be the new destination for many.
    KL was actually closed and that is a massive airport complex.

    [​IMG]

    Couldn't go back either.

    So here we are at home in a 14 day self isolation dictated by the powers that be.
    Glad we don't live in a 1 bed unit n a high rise somewhere.
    We may just eat on the balcony this evening.

    [​IMG]

    Maybe I will catch up with John next trip.
  9. brstar

    brstar Long timer

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    [​IMG]



    Since our fine governmenatal peoples have declared me guilty by association ?
    Or was that dissasociation?
    Since I maybe sick therefore I am?
    The punishment is to stay in my dwelling for 2 weeks just to teach me something.
    Hopefully they don't shut Australia down over the deaths of 12 china virus victims so far.
    I read that nearly 37,000 people have died in Australia so far this year of various normal? issues.
    So lets panic about some virus ok?
    Anyway I never did like the suspension that I cobbled together along with the rest of the cobbled outfit.
    So time to do something about it.
    [​IMG]

    [​IMG]

    Ex XS650 swingarm bushes etc.

    [​IMG]

    What was and is no longer.

    [​IMG]
  10. steam powered

    steam powered just a regular punk

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    Looking forward to seeing what you come up with.

    And not wanting to make this political, but please read up about this virus, it is a major problem. Left unchecked it could infect 30 - 40% of the population (that's symptomatic patients), in Australia that is between 7 440 000 and 9 920 000 people. Of those about 3.5% would be expected to die, for Australia that means 260 400 to 347 200 deaths. Worldwide this could kill more people than all the wars in recorded history.
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  11. brstar

    brstar Long timer

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    [​IMG]
    Little mate was making a fuss over something in the garden bed this morning.

    He had found a rat.

    Not a very healthy one though, something I confirmed with a length of pipe.

    [​IMG]
    In position.

    Though the piece of angle did not work out as is, so a larger one is in process now.

    [​IMG]

    Picked these up a little while back.
    Of a road king I think.
    The other shocks I trialed could easily be compressed with body weight
    Not these babies I only weigh a 100KG.
    I'm wondering if they are gas pressurized?
    It will be a bit of a process I think to trial different leverage percentages to see if I can use 1 or 2 shocks as either a mono setup or twin shock.
    Have some ideas so will see.

    The law of unintended consequences
    About day 3 of my Iso.
    Had a recurrence of an old back issue.
    Still another week nearly before I can get treated properly.
    Looking forward to be able to stand straight again.
    There will be other consequences no one thought about as well.
  12. FLYING EYEBALL

    FLYING EYEBALL out of step

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    If you pull those brass bits they should have oil in them, you can replace the bits with a Schraeder valve but only use a hand pump to fill.
    [​IMG]
    eye to eye probably 12"

    They tell us max here is 50psi or so iirc

    the moco sells a pump of course but they are proud of it as you would suspect.
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  13. steam powered

    steam powered just a regular punk

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    Seems nuts to me that the medical system can give ICU care to infected patients but can't protect themselves enough to perform physio on a possible case. Hopefully you have managed to get some pain meds and/or anti-inflamatories delivered.
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  14. WILL_S

    WILL_S OUTLAW POSTIE 001

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    Hang in there eh
    Lots of things are changing without making any sense
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  15. brstar

    brstar Long timer

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    Useful info Josh.
    I actually have a neat little hand pump (Scott) it is way over requirement at 600psi capacity.
    I bought it for my Fournales shocks.
    Just a bicycle air shock pump.
    But has a neat feature in that when it is screwed to a schraeder valve it holds the set air pressure by releasing the valve part before unscrewing from the stem.
    Hoping not to need that feature.
  16. brstar

    brstar Long timer

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    Cheers got some ibuprofen delivered.
    The nice sounding doctor (on the phone) warned me of dire consequences with the stuff.
    Can kill you apparently.
    It has helped a bit in that I am at least having a go in the workshop.

    There is a website that can show those recently returned into Australia and I suppose elsewhere if anyone one their flight has had the virus.
    Our flight is clean so far.
    A simple test would be good.
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  17. brstar

    brstar Long timer

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    Had to shorten the shaft holding the swingarm tube and bushes together.
    Then had to cut a new thread.
    All I have for 16mm is a coarse tap and die.
    It was quite the challenge to cut a thread on this high tensile ( I think ) Shaft.

    Glad I don't have a 20mm tap and die set.

    [​IMG]

    Tomorrow will look at the shock capabilities.

    [​IMG]
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  18. brstar

    brstar Long timer

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    [​IMG]

    Two fer one ratio???


    [​IMG]

    Didn't quite seem to get it.

    [​IMG]

    Almost 1 for 1 ??
    Sag at about 10% empty.
    Will aim for roughly 2 to 1 ratio with both shocks.
    The fat Harley shocks need space that is not currently there.
    5 inch grinder may help.
    Fitted new larger angle though it may get trimmed.
    Back is sort of livable at the moment.
    Be nice to go for a long bike ride soon if it is allowed.

    I see the Indian government has totally screwed their people by demanding a shutdown.
    It will cost many lives there.
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  19. brstar

    brstar Long timer

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    [​IMG]


    [​IMG]

    Hand making or rather remaking things is sort of a fun challenge.
    Not sure why I do it but this is it so far.
    Made it so I can slide the shocks 50mm/2" forward for more leverage if necessary.
    The fatter Harley shock has a tight clearance on the guard but I am thinking a little trimming should make it fit like a bought one.
    Just need a subframe to fit the top of the shocks to, while hopefully looking cohesive.
    Mind that is not something I seem to do.

    Day 14 today.
    Come sunset I will wander over to the bottle shop for a beer I think.
    The back came sort of ok, at least walking a little straighter now.
  20. brstar

    brstar Long timer

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    Its nearly 6 weeks since I went to Cambodia.
    On my 1st day out the place has gone nuts.
    Nice to be able to go for a walk.
    And to the Chiropractor.
    And to go renew my license even if it does not allow me to travel state wide let alone nation wide at the moment.
    Even got some bits for the sidecar.

    [​IMG]


    A simple enough looking component.
    Who has a length of 1/2" whitworth threaded rod laying about anyway?

    [​IMG]

    Then I had to go off the property to attend to business.
    Clashes on with the far shock to the sidecar body for now.

    [​IMG]

    A cheap linear actuator would be handy here.
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