Lukas' Ultimate DR650 Adventure build up

[NOSIGN]

G'Day Lukas,

have you tested the 320mm disc with 4 pot caliper on the 21" wheel in the dirt?

I bought a bargain moto-master kit and will probably try myself but seeking your opinion first. I have the option of using my brembo 2 pot.

The motomaster kit reads that you can re-use the original master cylinder, but you mentioned that the fluid capacity is not enough. I plan on using a 300EXC cylinder. Do you reckon it'll work?

Thanks for your advice - great write up!

[keithm1]

hey lucas
great thread ive a bit of a project going at the moment and reading this thread is giving me the little boost i need to get stuck in again
thank you

[LukasM]

Originally Posted by blackcap

what are your opnion on the brightness of the LED indicators? i just installed some and with the feeble amount of light they put out im a little worried that cagers will have a hard time seeing them. how do yours compare to the incandescent stockers?

The front ones are great and IMO even easier to see than the stock ones. The rear flush mounted ones are not ideal now that I am using a big top box on my rack. If I do it over I will put the same ones as I have on the front in the back as well.

Originally Posted by NOSIGN

G'Day Lukas,

have you tested the 320mm disc with 4 pot caliper on the 21" wheel in the dirt?

I bought a bargain moto-master kit and will probably try myself but seeking your opinion first. I have the option of using my brembo 2 pot.

The motomaster kit reads that you can re-use the original master cylinder, but you mentioned that the fluid capacity is not enough. I plan on using a 300EXC cylinder. Do you reckon it'll work?

Thanks for your advice - great write up!

Sorry for the late reply mate. I know that a few Aussie guys are using the Motomaster caliper in the dirt, although that is on 950 SE (a bit heavier than our DRs). They like them a lot and reported great feel and feedback. You might want to contact Knackers and read this thread over in Orange Crush: http://www.advrider.com/forums/showthread.php?t=271702

The Motomaster will work fine with the stock MC as it has smaller pistons than my Brembo 4 piston caliper.

By the way did I ever send you a picture of the caliper bracket?

Originally Posted by keithm1

hey lucas
great thread ive a bit of a project going at the moment and reading this thread is giving me the little boost i need to get stuck in again
thank you

Good stuff man, and thanks for the kind words!

Do you have a thread on your project?

[NOSIGN]

Thanks for the reply Lukas! I cant believe that I searched for motomaster 320mm and didnt pick up on that awesome thread! thanks for the link.

I'm yet to adapt the motomaster kit on the dr... actually the dr's still in bits, but I'm about to start work on it again. I'll see if i can use the stock MC and i'll experiment with the brembo 2 pot and mm 4 pot caliper.

Negative on the calipler photo. My forks are a bit on the odd or one-off side, and the caliper mounting is spaced at 65mm.

Happy twenty 10!

[MODNROD]

Gday Lukas, your the man!

I have my 2006 640 SM with the front wheel out, and a 2003 640 Adv 21" front wheel waiting to go in. Measured it all up for the spacers, I'll turn some up on the lathe, then the 21" wheel is in (and central). Unfortunately the Brembo hits the spokes on the bigger rim, coz of the bigger angle out to the rim obviously. I had thought of special spacers, but then the speed sensor is out of alignment, so I did think of grinding the beautiful gold Brembo (as you do, of course!) on the back for spoke clearance, but I measured up I need 2mm, maybe even 2.5mm. In your opinion, an opinion I value looking at your previous posts, will this seriously weaken the caliper, or is all well in Brembo-land?

The reason for the 21" front is the RallyMOTO I have my name down for in a few months time, my first , and the only other option is re-lace the Adv hub for a 19" rim to clear the spokes/Brembo and fit a 100/90x19 knobby, or fit a bloody great big balloon knobby rear tyre (120/90x17) to the standard 17x3.5" front rim. I'm actually running a Mitas E08 120/90x17 on there now for riding around on the dirt, so don't need a steering damper at all! Surface is hard pack covered in loose pea-gravel, and having never done high speed off-road on a bike before when everyone says "you what?!?", or "won't work, tyre too heavy, steering too slow", means nothing to me because I have nothing to compare it with! The 17" knobby does look cool though........ The standard 640 Adv 18" rear bolts straight in, so no problems there.

Your reply is eagerly awaited. Advice on tyre size for a dirt beginner and the whole rim size/tyre size/Brembo strength is all welcome.

Great thread man, keep up the good work.

[DRjoe]

There are 3 pot calipers that you can get that don't foul the spokes and i'm sure they would give plenty enough stopping power when coupled with a 320mm disk
This one is of a cbx1100xx

I couldn't find a relocate bracket so I made my own which might not be strictly legal but i'll paint it black and no one will ever know.

[CoastMountainGuy]

Originally Posted by LukasM

Finishing touches (for the supermoto setup, that is ):


The Suzuki POS clutch perch – which idiot had the idea to make it non-removable unless you take your grips off! – was replaced for an ASV unbreakable version. Luckily I was able to re-use my grip heaters.




I had to take out the adjustment bolt since it hit the big switch housing before reaching full travel:





Even a smaller allen head still hits. This works for now but I will have to come up with something better later:



.

Hi Lukas...Great build by the way! Sorry for dragging this one up from the past, but I'm hoping you can help me out with an ASV lever I'm trying to install on my DR650.

My problem is this: I can't for the life of me get enough tension on the clutch cable using the ASV lever. I have adjusted both the barrel on the cable body AND the barrel on the lever... What the heck am I doing wrong? For some reason, I just can't figure this one out...any ideas?

[LukasM]

Originally Posted by CoastMountainGuy

Hi Lukas...Great build by the way! Sorry for dragging this one up from the past, but I'm hoping you can help me out with an ASV lever I'm trying to install on my DR650.

My problem is this: I can't for the life of me get enough tension on the clutch cable using the ASV lever. I have adjusted both the barrel on the cable body AND the barrel on the lever... What the heck am I doing wrong? For some reason, I just can't figure this one out...any ideas?

Hi mate,

That one shouldn't be too hard to solve. Unhook the cable from the clutch perch, and then set the adjusters at the lower end so the cable is fully loose. Then simply move the lever on the splined clutch actuator by one spline or two, that should tighten the cable up nicely and give you plenty of adjustment for the future.

Cheers.
Lukas

[CoastMountainGuy]

Thanks Lukas!

I had a feeling it was just me... That just makes too much sense. I was concentrating too hard on just the clutch lever side of the system, and was forgetting about the end down on the engine case! Of course, you can just jump a couple of splines and everything can be adjusted from there...

Sometimes it just takes a nudge to make you see the problem from a different perspective. That's why this site is such a fantastic resource. So many helpful individuals willing and able to share their knowledge! Thanks again for the insight...

On a similar topic, were you ever able to sort out the clearance issue between the adjuster nut and the light switch housing?

Cheers,
Aaron

[vintagespeed]

great build Lukas, thanks! inspiring me with my new commuter!

[explr]

I was reading this and wondering how things turned out

[DRjoe]

he bought a ktm, bmw and a husaberg

which just proves the point that you need three eu bikes to do what one decent dr650 can do

[LukasM]

Originally Posted by DRjoe

he bought a ktm, bmw and a husaberg

which just proves the point that you need three eu bikes to do what one decent dr650 can do

Quite right Joe! I've since bought and built a couple of specialised bikes for each type of riding I like to do, but as a single do-it-all bike I still think the DR is hard to beat.

It's still in my garage right now, awaiting the arrival of a buyer (another ADVrider) from the US who will ride it around Europe and then Asia starting at the end of May. I'll go through it in the next couple of weeks and install some additional farkles that he sent me, will post an update once it's done.

Glad to see the DR live on, after all the work that I put in it would have been a shame to part it out!

[svestenik]

One question regarding your build :). Since DR 650 "second edition" (post 1996) are hard to find in Europe, what do you think about XF650 as a base for modification ?

I know that DR 650 (post 1996) and XF share similar engine, and I know that XF is more street oriented. But, if we give it more off-road biased suspension front and rear, and few other mods...

Can DR 650 Acerbis fuel tank be mounted on XF frame ?

[LukasM]

No idea on what interchanges to be honest, but I doubt (m)any of the chassis parts do.

IMO you will be much better off waiting for an SE to turn up, tons of parts and known mods for it out there.