The Real 650r Dakar ~ Ninja Morphed into a Desert Sled!

Discussion in 'Some Assembly Required' started by Gryphus1, Mar 10, 2016.

  1. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    This build will be the transformation of an 07 Kawasaki Ninja 650r. Almost a year ago I got into adventure riding, dual sporting, and single track riding. In doing so I discovered the wonderful world of ADVrider.com. One thing led to another, and all of a sudden I've replaced those sport bikes with off road bikes!

    After developing some off road riding skills, and kind of getting a taste of what type of riding I wanted to do I came to a few conclusions. Initially I thought I could have just one Do it all bike, but I was wrong. The more bikes the merrier! That being said, you a can only have as much bikes as you have storage capacity for, so right now I'm going to thin the herd. Ive come up with my ideal trifecta of bikes. A trail bike, commuter, and backcountry discovery route / two track type of machine, the last one being the soon to be 650r Dakar. Yea, BMW coined the name, but lets be honest.... is that really something to be compared to a Dakar bike? When I see a Dakar my eyes are immediately fixated on that fairing, the big tanks, and the all around badass-ness that comes with it.

    So, I guess the purpose of this build is to make a bike that suites my taste. It's gotta be "cheap"
    not a 500# Pig, has long maintenance intervals, and has the ability to make the guys on their $10,000 bikes jealous when they get passed. Should be easy enough right? Luckily for me there are a few other very well documented builds for these bikes. So I'm stealing the bits that I like from those builds, and adding in a few twist of my own.

    Build Specs

    Front Suspension: 03 Yamaha YZ 250 (stock springs for now)
    Rear Suspension: 08 Yamaha R1 (paired with a 900# versys spring)
    Front Wheel: 06 YZ 250
    Rear Wheel: Warp9 KTM 690 cush hub, custom spacers to sleeve the bearings
    Front Brake: 320 Warp9 rotor, KTM 450sxf complete front brake assembly caliper / S.S. line / M.C.
    Rear Brake: Single 220 mm petal disc with single-piston caliper
    Foot Pegs: 05 RMZ 450, paired with custom 1/4" plate steel brackets to lower the position.
    Swingarm: Stock, but has been Extended 2", Will need a 130 link chain kit to make this work.
    Exhaust: Modified stock header pipes (cut, bent, relocated) paired with a YZ450 fmf Exhaust
    Lights: ADV Monster Model 30 & 60, no Dimmers (let the light shine bright!)


    Before I bought this bike I had a Versys, and Two KLX250s. I use Versys as a daily rider, and it's served me very well. Which is one of the reasons I chose the ninja 650. For those of you who don't know the Kawsaki 650 parallel twin is super reliable, and makes some pretty good HP too. The KLX's that I have are also really reliable bikes, with higher maintenance intervals. They can pretty much do it all, but after a long weekend of riding the last thing I want to be doing is screaming down interstate on a 250. In June, I'm going to be going to an ADV meet up, but before the rally a group of us will be touring about the Pacific North West. At this point all the guys riding in the group are going to be on 600+cc bikes... I didn't want to be left behind in the open sections, so that's what led to me buying a salvaged 650r off of Copart, and scheming to build a bike. A few other reasons I wanted to build a bike as opposed to buying one so I could learn some very useful skills such as: precision metal working, composite forming, and tig welding. These were the majoring things that I wanted to learn to do. In my mind building a custom bike was the perfect chance to form together all of these skills.

    On to the build!
    #1
    Victusvita likes this.
  2. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    Here is how I got the bike, all the dust in every nook and cranny was free too. She was a real gem...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    I bought the bike without hearing it run, or even knowing if it would run...it was a salvage. I think someone stole it, and then was going to part it out, as you can see some of the body work is gone. The ignition cylinder was broken off, so I hotwired it quick, and hooked up a battery. It was a bit reluctant to start. Once it started the bike was smoking like a diesel, big black cloud of smoke after giving it any gas.

    Once I knew that it ran, I dumped out all the old gas... It was a nasty brown color, the inside of the tank wasn't rusted luckily. Put fresh gas in, looked over a few things and took it for a quick test ride up the road. All seemed good, so it's build time! Well... Disassembly then build. You all know how that works.

    I started in the order that I received parts. The first bits of goodies to arrive were the forks, new head bearings, and the front wheel.

    Dissembling, and removing the old stuff was pretty much straight forward.

    [​IMG]

    The front suspension swap involved removing the old races, and putting in new ones to fit the Yz stem. The whole process probably took 3hrs. The hardest part was removing the bottom bearing off the Yz stem. It's an interference fit, and was extremely hard to remove.

    [​IMG]

    [​IMG]

    [​IMG]


    Sent from my iPhone using Tapatalk
    #2
  3. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,818
    Location:
    Beaverton, OR
    :lurk
    #3
    Victusvita likes this.
  4. GR0NK

    GR0NK Got some screws loose!

    Joined:
    Sep 24, 2006
    Oddometer:
    8,681
    Location:
    Stuck in 80s
    Nice mancave. I guess some dick tried cutting metal on your bandsaw. :rofl



    Sean :bmwrider
    #4
    zzzak, Victusvita and L.B.S. like this.
  5. waylongway

    waylongway madmax

    Joined:
    Dec 16, 2009
    Oddometer:
    3,465
    Location:
    NorCal
    Love the shop......!! :tb Tools.Tools.Tools......:raabia
    #5
  6. JimVonBaden

    JimVonBaden "Cool" Aid!

    Joined:
    Feb 11, 2005
    Oddometer:
    76,684
    Location:
    Alexandria, VA
    Nice start! :thumb
    #6
  7. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    After getting the front end mounted up I decided to tackle the rear suspension.

    I ran over to harbor freight, and grab a spring compressor so I would be able swap out the regular r1 spring for the versys spring.

    Removing this spring turned out to be a real shit show. I should have took some photos, but I didn't.

    The jaws the harbor freight spring compressor barely latched onto the spring, and after a couple of attempts I was finally able to compress it enough to get the clip out. In the process I scratched a lot of the paint off the spring. There's no way I'd be using that spring compressor to put the new one on.

    After Googling "motorcycle spring compressors" for about 10minutes, and wondering how the heck I was going to get that new spring on... I then realized I could turn the shock upside down, so that the spring was contacting two plates, but is still open from below, so that when I compressed the spring and shock together in the big press you might have seen in the photos that it gave me enough room to slip the retaining clip on.

    I wish I would have thought of doing this for removing that old spring. It was 10x easier!

    [​IMG]

    The r1 shock utilizes a needle bearing with a bushing on one end, and a damped runner bushing on the other end. I ended up pressing the damped bushing out, and boring it out to 12.05mm, and the same goes for the bushing that works with the needle bearing.




    Sent from my iPhone using Tapatalk
    #7
    Victusvita likes this.
  8. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    I didn't get around to ordering a rear wheel until later in the build, so I ended up throwing a TKC 80
    On the rear rim. It helped offset the huge displacement between the front 21" and the stock 17"

    Here's some photos of the bike with the r1 shock installed, along with that meaty rear tire.

    [​IMG]

    [​IMG]

    I never liked the tail sections in the other builds that I've seen, so as you can see I'm starting to dabble with some different ideas.


    Sent from my iPhone using Tapatalk
    #8
    sebwiers and Victusvita like this.
  9. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    Today I got my ADVMonster lights! Thanks Sanjoh. Tonight I tested them, man those things are bright!

    I went with the model 44 & 30. The plan is to stack both lights, with the 44 below, and the 30 above.

    I'll be making up some sort of dimmer for the 44, as it is going to be the running light. In its current state it's way to bright!

    So tonight I organized the work area a little bit, and started to layout the Nav tower brackets.

    [​IMG]

    [​IMG]


    Sent from my iPhone using Tapatalk
    #9
    Victusvita and invisa-bill like this.
  10. Bt10

    Bt10 Been here awhile

    Joined:
    Dec 18, 2012
    Oddometer:
    285
    Location:
    Saranac,MI
    :lurk:dukegirl
    #10
    Victusvita likes this.
  11. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    2,788
    Location:
    Mid Wet Or A Gun
    :nod

    Pleasant surprise to see you again at our Two Wheel Tuesday meatup at Flat Tail Brewery in Corvallis last night.

    Did you pick up the un-catted KTM ADV 9XX mufflers last night, or did you get the stockers?

    Reason being, we had one un-catted and it gave you a reference where to cut to gut the cat.

    If you need, I can get the dimension for you.

    Cow A Bung Ga.
    #11
  12. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    I got one of the regular cans, its still got a cat inside of it. Zuber showed me where I should cut, and also gave me a few other helpful hints!
    The whole idea of using a 9XX can came from this link : http://advrider.com/index.php?threads/ktm-990-adventure-2-1-with-stock-exhaust.1024858/page-2

    Got a couple other good ideas from that thread too, like having a "dual exhaust" setup, were the left exhaust is (hollowed out), so that it can be used as a toolbox, or a gas tank; given that it has the correct modification done to it. Both of which I don't think I'll be able to do with that 525 rear fender section, it's pretty narrow in comparison to the 950's & 990's.

    So I guess the plan is now to mount the exhaust down low. This will actually follow the ascetics, and design of most Dakar bikes.. and it keeps the weight of the KTM can down low!
    #12
  13. larryboy

    larryboy Chopper Rider

    Joined:
    Jan 9, 2005
    Oddometer:
    20,711
    Location:
    Über Alles,California
    Here's my homemade spring compressor. It had to be strong since I was installing a 1200 pound spring on my GoldWing.

    image.jpg

    How's the rake/trail coming out?
    #13
    Gryphus1 likes this.
  14. Grahamcracker

    Grahamcracker Been here awhile

    Joined:
    Mar 10, 2014
    Oddometer:
    488
    Location:
    PDX
    Looking sweet J! Are you riding this to Crooked River? I'm debating wether to ride out or not, someone has to prove the worthiness of the almighty twofiddies! I've seen some pretty convincing rubbermaid rubbish bin fairings, it could maybe make a good testing base and then fiberglass it if you like it.
    #14
  15. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River

    Chances are it won't be at crooked river.. but who knows. Probably going to ride a 250 over, that or take the Versys / trialer / 250... my only concern being snow.

    I've got some foam to make a custom plug for the fairing(s), but I'm still waiting on my ABS (for the Nav tower), and my epoxy to show up. I did find a big roll of carbon fiber on my front door the other day :clap..

    About that "testing the worthiness of the almighty twofiddies" I think I proved that on my L.A. Adventure with the two 600+ miles days I did awhile back :super
    #15
  16. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    2,788
    Location:
    Mid Wet Or A Gun
    Gray+1 Wrote:

    "It's gotta be "cheap"not a 500# Pig,"

    Soooo...got any means to weight it now?
    Just noisy... Been eye balling this motor for a few years...but in flat track trim..low and lite.
    #16
  17. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    Update:

    Haven't been wrenching lately. Busy with work / one of the ADV rally's that took place this weekend.

    On a side note more parts have been trickling in, including this new 690 wheel that just showed up!

    [​IMG]


    Sent from my iPhone using Tapatalk
    #17
    Foxed101 likes this.
  18. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    2,788
    Location:
    Mid Wet Or A Gun
    Oh good, you made it back to this side of the Cascades thru the snow, trailering a motorcycle, with a motorcycle.

    Some are still stuck in the snow, without pulling a trailer, with a motorcycle.
    #18
  19. Gryphus1

    Gryphus1 I'd rather be riding

    Joined:
    Mar 3, 2015
    Oddometer:
    982
    Location:
    Dirty Old Van Down By the River
    @DiggerD

    I wimped out (or just used my brains), and decided to take the safe route by riding / pulling the motorcycle(s) up to Portland, and then hitching a ride with a Portlander over to the dry side.

    [​IMG]
    #19
  20. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    2,788
    Location:
    Mid Wet Or A Gun
    Smart man.
    I was sliding my front tire this weekend on my CBRXX without snow, or luggage.
    Still cool and wet ot.

    Wait !
    WTF is that truck spare tire doing on the trailer, as if you don't have e-nuf weight.... ? ? ?:lol3:lol3:lol3


    Want, below...with a plate, and more gas under the seat.



    [​IMG]
    #20