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Old 01-02-2012, 07:47 AM   #1
Daithi OP
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Location: Cork, Ireland
Oddometer: 175
Thumb DRZ400 Forks, Rear Disk & HPN Tank on a R100 GS Paris Dakar




I took this bike (above) out for a spin on a few trails and found the suspension and brakes to be lacking so I did a search on here and found the thread on
GSifying an RT link: HERE which inspired me to have a go myself. I checked out Ebay and a few local classified type websites and came across a set
of DRZ400E forks and yokes, a Remus silencer, a HPN Tank and saddle.

I stripped all the PARIS DAKAR stuff (I have it all complete and stored safely), even before I tried the forks out I had to see how the HPN tank would fit.
The oil cooler was in the way, and in moving the cooler this negated some of the need for the crash bars.(need to source a bolt on sidestand).

I straightened out the tubes to the cooler and reversed them to allow the cooler to be mounted under the headstock, much like the Touratech kit.
I did consider putting a bypass block on it as we don't get the temperatures here to need an oilcooler, but patience isn't a trait of mine so this will
have to do for a while.

Once the DRZ stuff arrived I put it together thinking all I'd beed is a couple of spacers to make up for a longer stem
length, the GS bearing size is 52x28x16 but the DRZ bearing size is 55x30x16.... luckily there is a 52x30x16 available
which got me sorted, popped out the old races and in with the new.




The longer stem needed packing of about 5mm so I routed in the boxes of nuts and bolts and found a 6mm collar with an ID of 30mm, greased the
bearings and bolted it all together.
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Old 01-02-2012, 07:48 AM   #2
Daithi OP
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The next problem was the forks and clamps didn't come with a brake system or an axle bolt and neither did the front wheel, I now have a DRZ
which has now become a temporary donor bike.

The silencer, the original was rotten with rust, but the one I'd picked up was perfect for what I wanted but was way too long, so I drilled out the
rivets and chopped 4 inches off and re-riveted it (below).



I had a couple of TKC80's from another bike so I put them on, I had a target date for New Years Day for a spin so I did take a few short cuts.

I had a set of Magura bars from the XChallenge and fat bar-adapter lower clamps but no top clamps so I had to make them, luckily I found the
right size drill in work, SORTED.

The next problem was the Throttle Vs Brake master cylinder, I wanted to use the DRZ brake system but the BMW unit incorporates the brake and
throttle with two cables running to a carb each.




I used the DRZ master cylinder and a borrowed spurious single cable throttle (thanks Gunner) along with the splitter from the choke to cable the carbs.
Worked a treat, looks a bit home made but shouldn't give any trouble.

I never liked the bulky rear mudguard so I found and old tail-piece from a DR which I used, so all the original plastics are now in a box safe and sound.

I've a bit of tidying up to do with switches and mudguards and I like to put a disk on the back like Phreaky Phil did but for the time being I'm delighted
with the results. I've taken the bike for a spin on the road and it handles very well, there's a lot more ground clearance, infinitely lighter and the brakes
are fantastic, I'm looking forward to a trail ride on it.

Daithi.
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Old 01-02-2012, 09:25 AM   #3
bgoodsoil
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Nice! Those fork tubes are monstrous. Are you doing anything to lower the ride height? I have to imagine it's a little chopperesque with the stock height.
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Old 01-02-2012, 10:48 AM   #4
Daithi OP
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Thumb

Quote:
Originally Posted by bgoodsoil View Post
Nice! Those fork tubes are monstrous. Are you doing anything to lower the ride height? I
have to imagine it's a little chopperesque with the stock height.
I was worried that it would mess up the handling and untill I get out on a trail I won't know for certain, but on the road it felt
fantastic, and I was very conscious of the possibility that it would feel chopperish. I have long legs so the height is a good
thing, between putting the spacer on the top and the forks pushed through the top yoke by 40mm that's as much clearance
as I'm willing to lose, I'd like to raise the back rather than drop the front. I have and adjustable torsion strut and I'm going
to look at replacing the stock rear shock. It genuinely feels very good but needs to go offroad to see for sure, I do however
need handle bar risers.


Really love this bike, can't help but grin when I get on it.
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Old 01-02-2012, 11:03 AM   #5
One Less Harley
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I have a DRZ and am really curious how well the front brake stops the big bike as on the DRZ the brakes aren't anything to write home about. Good enough on the trail but lacking on the road.
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Old 01-02-2012, 11:25 AM   #6
Daithi OP
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Quote:
Originally Posted by One Less Harley View Post
I have a DRZ and am really curious how well the front brake stops the big bike as on the DRZ the brakes aren't anything to write home about. Good enough on the trail but lacking on the road.
I suppose it's all relative to what you expect from them. I have a DRZ that I take out for handy enough trails at very
moderate speeds and have never found them wanting but the Brembos on the GS were crap which, combined with the
poor suspension, is what made me do this. I know there may have been better choices out there but I got the Forks
and Yokes for very very little money and I'm delighted with the result.

In answer to your question, it now feels possible to do a stoppie on the GS.
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Old 01-02-2012, 01:01 PM   #7
bgoodsoil
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I've got a dr650 front end--similar brakes. I've done stoppies but I had to get on a downhill and lean waaaay forward. Scared the crap outta me!
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Old 01-02-2012, 03:03 PM   #8
bereahorn
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Old 01-02-2012, 07:26 PM   #9
Beater
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This is really weird. I've been used as 'inspiration'.



Rock on Daithi! Personally I love those forks. I have a '91 GS and I really think that the DRZ forks are a big upgrade. Big thick and just feel RIGHT. Continue!!!
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Old 01-02-2012, 09:11 PM   #10
Stagehand
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Nice bike.



LETS RACE IT
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Old 03-12-2012, 04:35 AM   #11
Daithi OP
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I made up a bashplate for the HP1...........



......... and while I'll admit it ain't pretty it's certainly functional.






I've bodged the original oil-cooler pipes and managed to get the oil-cooler up out of the way on the downtubes.



I've taken the bike out for a few spins off-road and it's brilliant, need to sort out the back suspension though
but need to maintain the Ultra low budget, any ideas ?.
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Old 03-12-2012, 05:41 AM   #12
hardwaregrrl
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For economical, people like the YSS shock.
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Old 03-12-2012, 06:25 AM   #13
Podmiester
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Thumb Remus Can.

Nice bike Daithi.

I fitted a Remus can to my R100R a couple of years ago. Must say it increased the power performance of the bike.

Rgs Podmiester
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Old 03-12-2012, 10:37 AM   #14
subagon
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Quote:
Originally Posted by Daithi View Post
I stripped all the PARIS DAKAR stuff (I have it all complete and stored safely), even before I tried the forks out I had to see how the HPN tank would fit.
The oil cooler was in the way, and in moving the cooler this negated some of the need for the crash bars.(need to source a bolt on sidestand).
Bolt-on R100GS sidestand here.
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Old 03-12-2012, 11:30 AM   #15
Daithi OP
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Quote:
Originally Posted by hardwaregrrl View Post
For economical, people like the YSS shock.
If I can find 'em this side of the pond and they're cheap enough.....
Quote:
Originally Posted by Podmiester View Post
Nice bike Daithi.
I fitted a Remus can to my R100R a couple of years ago. Must say it increased the power performance of the bike.
Rgs Podmiester
Thanks, the Remus was borne of necessity, but it's lighter and tidier and not rotten with rust.

Quote:
Originally Posted by subagon View Post
Bolt-on R100GS sidestand here.
Brilliant, could solve a lot of problems in one fell swoop, thanks Mike.
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