ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 06-14-2007, 04:42 PM   #1
LukasM OP
Beastly Adventurer
 
Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,331
Lukas' Ultimate DR650 Adventure build up/ rebuild

So I am finally starting my next project. I would like to share this with you guys and hope to inspire some of the less mechanically inclined ones. It should help people working on their DR's as well as show you what NOT to do as I am sure to make plenty of mistakes.

The bike is a 96 DR650SE (except for a gasket the exact same thing Suzuki is still selling today) that I bought last winter real cheap. I plan on doing a trip from Vienna - Capetown down East Africa sometime this fall. I thought it would be a smart idea to really get to know the bike, replace all the wear items and improve some of the DRs weaker areas.

The plan includes the following upgrades:

Wheels:
Excel 21" front and 18" rear wheels for offroad
Excel 17" front and rear for supermoto
Front brakes:
Brembo 2 piston with 300mm rotor, 13mm (?) MC for offroad
Brembo 4 piston with 320mm, 16mm (?) MC for supermoto

WP 43 USD Forks with 20mm offset, custom valving and external preload-adjusters
Pro Taper Easton 28mm bars
Ufo hand guards with aluminum inserts
KTM EXC switches
Touratech IMO 100R300 with switches
Garmin 60CSX GPS with Touratech mount
IMS tank (and later Safari)
Wilbers rear shock
Hepco & Becker luggage rack
SW-Motech quick release side racks
Replace worn bearings, regrease
Metal base gasket
Holeshot Performance header
Aftermarket exhaust (probably LeoVince)
Dynojet kit

Also, since I have a scale in the garage and somewhat of an obsession with weight (being a wannabe racer), I will keep a running tab of the part weights as I add them to the bike. Maybe they will help someone who is trying to get the weight down to something more off-road worthy:

Frame (helmet lock yet to be taken off): 16 kg
Wilbers Shock: 3,4 kg
WP 43 Forks with triple and handlebar mount: 12,5 kg
Stock engine with oil and oil cooler: ~50kgs!
21" complete Excel front wheel with tire (90% thread): 9,1 kg
IMS Tank, plastic cap, petcock: 2,9 kg (I read somewhere that stock is 4,5 kg)
Left side case saver: 0,1 kg
Ufo hand guards: 0,6 kg
Wiring harness: 1,1 kg
Stock Pegs: 1,1 kg
Sidestand: 0,6 kg
Throttle tube with cables: 0,4 kg
Front MC: 0,4 kg

Removed:
Plastic undertail: 0,7 kg
Rear handles: 0,75 kg
Sidestand safety switch: 0,1 kg
__________________
RTW trip blog: https://www.facebook.com/AroundTheWorldWithLukasM

LukasM screwed with this post 06-16-2007 at 07:04 PM Reason: Updating
LukasM is offline   Reply With Quote
Old 06-14-2007, 05:11 PM   #2
LukasM OP
Beastly Adventurer
 
Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,331
The "before" shot and the tear down

So this is what she looked like the day I bought her. What can I say, she was really cheap



The previous owner clearly felt no love for this bike, so there were lots of little nags and minor issues. The engine however felt solid and made no strange sounds, so I thought it was a good candidate for my planned project. I does however have a leak, which I think comes from the shifter shaft area. Kind of hard to tell as the whole thing is covered in grease and dirt.

Since the frame had lots of rusty areas and a hideous purple color (looks much worse in real life than the pictures), I decided to tear her down completely and start fresh.



These are various shots that show what mess I had to deal with. And this is after several tries with the pressure washer..



Wiring was messed with as well:



Almost done, the beast (sort of ) and its heart:



__________________
RTW trip blog: https://www.facebook.com/AroundTheWorldWithLukasM

LukasM screwed with this post 06-21-2007 at 07:51 PM
LukasM is offline   Reply With Quote
Old 06-14-2007, 05:13 PM   #3
RiDR
The Himalayan what?
 
RiDR's Avatar
 
Joined: Mar 2007
Location: 45.55397,-78.59676
Oddometer: 592
RiDR is offline   Reply With Quote
Old 06-14-2007, 05:44 PM   #4
LukasM OP
Beastly Adventurer
 
Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,331
Since the dissassembly about 3 months have passed, I have accumulated lots of the parts I need (much of the delay due to a very unreliable supplier ), the frame is back from powdercoating and of course I have no memory anymore which part goes where

This is what the frame looks like after sandblasting and powdercoating. The finish appears to be pretty tough so far and I think the dark silver color came out nice:





Next up were the WP forks. As I have posted on here before and member Gsuser did on his bike, they fit on the DR650 very well. You can re-use the stock DR races, the lower KTM seal and bearing on the KTM stem, and the KTM upper bearing with the DR seal on top. Looks like this when done:





Put the upper triple on and slide the forks tubes in, gotta love the USD look!





The swingarm was wire brushed, and the seals + bearing cleaned and re-greased. Also put the pimpin' shock on for a trial fit.

__________________
RTW trip blog: https://www.facebook.com/AroundTheWorldWithLukasM
LukasM is offline   Reply With Quote
Old 06-14-2007, 07:22 PM   #5
FatChance
Road Captain
 
FatChance's Avatar
 
Joined: Jun 2003
Location: Durango, Colorado, USA
Oddometer: 10,022


Great project! Keep the updates coming!
__________________
Pain in the Butte Ranch
Durango, Colorado

- Calculated risk or forbidden fruit?
FatChance is offline   Reply With Quote
Old 06-14-2007, 10:12 PM   #6
Max Kool
Xtankteam™
 
Max Kool's Avatar
 
Joined: Jan 2004
Location: Los Angeles
Oddometer: 3,227
Great thread Lukas!!

Keep them pictures coming. You're doing a great job!
Max Kool is offline   Reply With Quote
Old 06-14-2007, 11:42 PM   #7
warnabrother
.. if you see the Rozzers
 
warnabrother's Avatar
 
Joined: Dec 2006
Location: Morn. Pen. Melbourne
Oddometer: 2,022


mmm... WP's on a DR
__________________
bikeless...
warnabrother is offline   Reply With Quote
Old 06-19-2007, 05:37 AM   #8
perryg114
Adventurer
 
Joined: Oct 2005
Location: New Market, AL (near Huntsville)
Oddometer: 95
You really need some guards for that bike.

http://www.motorcycleproducts.org/Ne...50_guards.html

Perry


Quote:
Originally Posted by LukasM
So I am finally starting my next project. I would like to share this with you guys and hope to inspire some of the less mechanically inclined ones. It should help people working on their DR's as well as show you what NOT to do as I am sure to make plenty of mistakes.

The bike is a 96 DR650SE (except for a gasket the exact same thing Suzuki is still selling today) that I bought last winter real cheap. I plan on doing a trip from Vienna - Capetown down East Africa sometime this fall. I thought it would be a smart idea to really get to know the bike, replace all the wear items and improve some of the DRs weaker areas.

The plan includes the following upgrades:

Wheels:
Excel 21" front and 18" rear wheels for offroad
Excel 17" front and rear for supermoto
Front brakes:
Brembo 2 piston with 300mm rotor, 13mm (?) MC for offroad
Brembo 4 piston with 320mm, 16mm (?) MC for supermoto

WP 43 USD Forks with 20mm offset, custom valving and external preload-adjusters
Pro Taper Easton 28mm bars
Ufo hand guards with aluminum inserts
KTM EXC switches
Touratech IMO 100R300 with switches
Garmin 60CSX GPS with Touratech mount
IMS tank (and later Safari)
Wilbers rear shock
Hepco & Becker luggage rack
SW-Motech quick release side racks
Replace worn bearings, regrease
Metal base gasket
Holeshot Performance header
Aftermarket exhaust (probably LeoVince)
Dynojet kit

Also, since I have a scale in the garage and somewhat of an obsession with weight (being a wannabe racer), I will keep a running tab of the part weights as I add them to the bike. Maybe they will help someone who is trying to get the weight down to something more off-road worthy:

Frame (helmet lock yet to be taken off): 16 kg
Wilbers Shock: 3,4 kg
WP 43 Forks with triple and handlebar mount: 12,5 kg
Stock engine with oil and oil cooler: ~50kgs!
21" complete Excel front wheel with tire (90% thread): 9,1 kg
IMS Tank, plastic cap, petcock: 2,9 kg (I read somewhere that stock is 4,5 kg)
Left side case saver: 0,1 kg
Ufo hand guards: 0,6 kg
Wiring harness: 1,1 kg
Stock Pegs: 1,1 kg
Sidestand: 0,6 kg
Throttle tube with cables: 0,4 kg
Front MC: 0,4 kg

Removed:
Plastic undertail: 0,7 kg
Rear handles: 0,75 kg
Sidestand safety switch: 0,1 kg
perryg114 is offline   Reply With Quote
Old 06-19-2007, 08:46 AM   #9
Zapp22
ZAPP - Tejas
 
Zapp22's Avatar
 
Joined: Oct 2004
Location: Tejas Hill Country
Oddometer: 13,615
Nice products, but what this, and ALL DR's need is a quality set of crashbars, which I have yet to see. The low-slung "engine guards" [what they should properly be called] are only slightly effective for the engine and are downright dangerous for everything else as they cause the bike to roll right over on the tank, handlebars, etc [ask me how I know...].


Quote:
Originally Posted by perryg114
You really need some guards for that bike.

http://www.motorcycleproducts.org/Ne...50_guards.html

Perry
__________________
Zapp
"I will not let the White City fall... nor our people fail.” - Aragorn
K4 WEESTROM Stealthfighter Black -SOLD - Invisible to Radar, '02 DR650SE SOLD ,'Ole 97' DR650SE My Fave K5 WEESTROM ADVbomber
Zapp22 is offline   Reply With Quote
Old 06-19-2007, 10:28 AM   #10
shoco
Not So Gnarly Adventurer
 
shoco's Avatar
 
Joined: Nov 2005
Location: Southern California
Oddometer: 467


Awesome thread. Can't wait to see the progress.

LOTS OF PICTURES PLEASE!
shoco is offline   Reply With Quote
Old 06-21-2007, 07:12 PM   #11
LukasM OP
Beastly Adventurer
 
Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,331
Quote:
Originally Posted by perryg114
You really need some guards for that bike.

http://www.motorcycleproducts.org/Ne...50_guards.html

Perry
Perry,

I am proud to say that I own the only one of your case savers in Austria (at least as far as I know)!
__________________
RTW trip blog: https://www.facebook.com/AroundTheWorldWithLukasM
LukasM is offline   Reply With Quote
Old 06-21-2007, 07:18 PM   #12
LukasM OP
Beastly Adventurer
 
Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,331
I have worked on the bike quite a bit since the last update. Only had the camera with me today though, so I decided to wait for some pictures before posting again.

There has been progress but also quite a few setbacks, so LEARN FROM MY MISTAKES!!!

First up was the rear shock linkage. I didn’t notice any problems with this before taking the bike apart, but decided that a clean and regrease would definitely not be a bad idea.






When I had taken it apart to start cleaning the bearings, I saw that one of them was missing two needles. Of course they were nowhere to be found, damn! I guess that they fell out during disassembly.






So I had to wait a couple of days for a replacement to arrive at the dealer. Once I had that, I just took out two needles and put them in the old bearing cage. I didn’t have a bearing puller and there was no wear on the bushing as far as I can tell, so I hope that this won’t be a problem.






Stuffed them full of grease and put the linkage back on the bike. Hope I did it right









__________________
RTW trip blog: https://www.facebook.com/AroundTheWorldWithLukasM
LukasM is offline   Reply With Quote
Old 06-21-2007, 07:44 PM   #13
LukasM OP
Beastly Adventurer
 
Joined: Nov 2006
Location: On a RTW ride - currently Central Asia
Oddometer: 5,331
Next was the front wheel. The one I have is from a 2005 EXC, which comes with a 26mm axle that fits into WP 48 forks. My WP 43s have a 20mm axle, and there is no factory solution to use the newer style wheels. The other way is easy with fork bushings but I will either have to make some custom spacers or re-lace the wheels with a 20mm hub. Either way a PITA!

I tried to fit the engine (now sporting the lovely metal base gasket) into the frame from the left side as the factory manual states, but managed nothing other than to scratch the frame. Turns out the powder coat is not as tough as I had hoped! Tried it again from the right side, and with a bit of wiggling got it in there. It is definitely not light, with the oil cooler and oil it weighs about 110 lbs.







As you can see in the last picture, I also trial mounted an old handle bar I had laying around while waiting for my Pro Taper to arrive. This is when I came across another problem: The mounting kit attaches with a nut from the lower side, which will contact the Suzuki steering lock receiver on the steering stem.







I took out the grinder and tried to remove as much as possible while damaging as little of the new PC finish as possible. Came out ok and there is plenty of clearance now (but my bearings don't fit, but I will post about that again in more detail). At some point I plan on mounting a Rallye style fairing on the front, so I will probably have to weld on some kind of bracket anyway.
Another solution would be to use an EXC or SX upper triple like Gsuser (http://www.advrider.com/forums/showt...34#post4065534), they have the bars solid mounted from the top only (LC4 is rubber mounted with a through-bolt and nut).






While having the grinder out, my weight phobia gave me some more stupid ideas. With a lot of restraint I only went through with one of them: Removing the helmet lock! I never use it, and the powdercoaters didn’t mask it off properly so it wasn’t working anyway.






The result: ½ a pound less! Would have hoped for more, but better than nothing. Still gotta touch up the frame here as well so it won’t rust.





The bike is farther alonng already, but the camera battery died, so you can read and see more pictures next time. Here is a small sneak preview

__________________
RTW trip blog: https://www.facebook.com/AroundTheWorldWithLukasM
LukasM is offline   Reply With Quote
Old 06-21-2007, 11:27 PM   #14
sixer
I suffer from Ainrofilac
 
Joined: May 2006
Location: CenCoCal
Oddometer: 1,220
Looks great with the WP forks. I can't wait to see the finished product. Keep at it.



__________________
"There are no such things as accidents—just two people competing for the same point on the space-time continuum."

Support your local Search and Rescue Teams.
sixer is offline   Reply With Quote
Old 05-17-2009, 06:46 PM   #15
moralesxr600
Nahuelbuta
 
moralesxr600's Avatar
 
Joined: Feb 2008
Location: Concepción, CHILE
Oddometer: 50
Quote:
Originally Posted by LukasM

IMS tank (and later Safari)
and Do you get the SAFARI tank? any pictures?
__________________
Cuando vengan a Chile, pasen a verme!!
http://picasaweb.google.com/riobiobio
moralesxr600 is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 12:48 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014