DR650 790 Big Bore Installation and Review

[planemanx15]

EDIT: Video of the build here: http://www.youtube.com/watch?v=G8xE4ZwgbdQ

The minute I saw the 790cc kit on Procycle.us, I knew that needed to go on my bike. So now, some time has passed and everything I need to make that kit happen has lined up. I ordered my kit last week, and it should be arriving by this Friday (pending my mailman doesn't fall asleep on duty again, true story). I have noticed there isn't much information out there documenting the installation for those that want to do it, but are hesitant. I will be documenting my installation with pictures and videos, and finally give a review of the product after the installation.

To give you an understanding of my skill level: I have an intermediate level of understanding mechanics, and have worked with tools my whole (short-thus-far) life. I have researched for hours the DR650's engine, have read the DR650 thread, and have read the service manual cover to cover. This will be my first time taking apart a 4 stroke engine. I have installed a new piston and rings on a 50cc 2-stroke scooter, but the lack of a timing chain or valves made that job silly easy.

About my bike:

For those that don't know, I bought my 2000 DR650 in October of 2010. She has 20,000 miles and cost me $1800 (neg down from $2400 )

How she looked the day I bought her home (next to my custom dr200 military edition):



How she sits today (Before my Hayabusa muffler installation):



As you can see, a lot of work has gone into this bike. I bought the bike to start off doing more trips and trail riding. Since buying it, property owners and local government has closed down all the shady trails in the area, and made it impossible to go off road. I have hear of instances where DEC officers will sit on the trail, pretending to be hurt, and when you stop to help them, they zip tie your clutch and take you away.... not worth it. I bought a v-strom 1000 when the trails started to close, but most of the time, found myself back on the DR, loving its ride. 1500 miles on the V-strom later (and 1 road trip) and she was history, sold to a guy in Jersey. I used part of that fund to spruce up the DR making it more road friendly. I bought the TM-40 pumper from Procycle, redid the suspension, new supermoto rear and 19" front, built a custom windscreen, and outfitted the bike with a V-strom seat among other things. Last summer I did 1000 miles in upstate New York, about 200 or so was 2 up with my girlfriend, Chrissy. She loves the way the DR rides, and actually prefers it over the Vee. We had no problem going upstate, but once the hills started, you can tell that engine was struggling.

That was the tipping point. I knew this kit has to be ordered if I wanted to keep riding together and enjoying the trip. I thought about a V-strom 650, but I would want a 2012+ (think they are hotter) and I don't feel like financing while starting to make a life. Plus, my DR is MY DR... There are no others like it in the world.

I also ordered with the Bike bore kit:

Barnett Clutch and springs
New hotter iridium spark plugs
10 pack of oil filters
valve o-rings
fuel filter (never has one on my bike, i think its about time)
timing plug (destroyed mine)
and a valve tool.

My DR has about 29,XXX miles on it.

I am planning on installing all of the above and:

Wrapping the exhaust pipe
Sound dampen the skid plate
Clean up some of my wiring
Check on the NSU


I hope you guys and gals find my thread to be informative and helpful. I will probably start\finish the rebuild on Friday the 15th. I will keep y'all posted!

[Mr. Canoehead]

Subscribed!

I have been thinking about this as next winter's project (doing RMZ forks this year). If you are spending the money on the BB kit, you should also look at changing out the cam. The stocker just won't feed that beast.

[Rob.G]

Also subbed! I plan to do this over next Winter.

Rob

[planemanx15]

A nice box came today....





Thanks procycle for the stickers!!! I was planing on having them made..

Luckily it came before this...



Snow is about 16" right now, and predicted to get more over night. Ill be worrying about getting this stuff out first then do the kit a week from today.

Opening the box and actually seeing everything was a bit intimidating. Seeing all the clearance numbers, and all the parts, all I was thinking was "I hope this isn't a waste of $1200".. My concern right now is getting the rings on right, and making sure everything is right in that aspect. I didn't take a picture of the piston, but trust me, it's a work of art. Really beautiful piece of metal.

The cylinder is nice, and really clean. I fit the piston in the cylinder, and it's nice and sung, ill get out the gauges later and see how it really measures.

[Rob.G]

What's the story on the cylinder? Have you had it bored and sleeved, or was it just the sleeve you tested the piston fit in?

Rob

[DisTech]

[planemanx15]

Originally Posted by Rob.G

What's the story on the cylinder? Have you had it bored and sleeved, or was it just the sleeve you tested the piston fit in?

Rob

Procycle has two cylinder exchanc methods, I went with option #2. They sent me a clean bored out cylinder, sleeve already installed, and I will return my cylinder to them. Pricycle continues to amaze me. I was told on the phone don't expect the package to go out until Wednesday because we don't have a cylinder yet for you. Later that day I got an email saying my package shipped. After a quick Email to them, I found out the cylinder was already in the box ready to go. I love the "under-shoot, over-produce" business model!

See this link: http://www.procycle.us/info/articles...-exchange.html

[Rob.G]

Nice! Last I had heard, they weren't offering that... so that's great news.

Since I'm only an hour away from them, I'll probably just pull my cylinder and drive down there when I'm ready to get the stuff.

Rob

[planemanx15]

I bought the hotter iridium plugs. Should I have gone with the standard?

[Jeathrow Bowdean]

This is cool stuff. I won't be able to sleep tonight after reading about the 790cc power kit. "Oh My God." I hope he has one for me next year. Ha Ha.

From Jeathrow Bowdean

[GB]

We have a whole forum devoted to political b.s. in the basement, you have a political rant, take it to CSM and let the bike talk continue here... comments have been punted.

[neo1piv014]

Can't wait to see how this goes. I never knew about the cylinder exchange thing either. A couple hundred bucks for peace of mind isn't exactly a bad deal.

[neo1piv014]

Originally Posted by planemanx15

I bought the TM-40 pumper from Procycle, redid the suspension, new supermoto rear and 19" front, built a custom windscreen, and outfitted the bike with a V-strom seat among other things. Last summer I did 1000 miles in upstate New York, about 200 or so was 2 up with my girlfriend, Chrissy. She loves the way the DR rides, and actually prefers it over the Vee. We had no problem going upstate, but once the hills started, you can tell that engine was struggling.

Wait...how in the hell did you get a VStrom seat on there? I cannot stand the DR650 seat, and upgrading to a Corbin didn't help a bit. The few VStroms I've ridden, however, had very comfortable saddles. Can you give us any info on that piece of work? Friggen awesome.

[planemanx15]

Originally Posted by neo1piv014

Wait...how in the hell did you get a VStrom seat on there? I cannot stand the DR650 seat, and upgrading to a Corbin didn't help a bit. The few VStroms I've ridden, however, had very comfortable saddles. Can you give us any info on that piece of work? Friggen awesome.

see this thread post number 459 and on.. Page 32 also has some pics

http://advrider.com/forums/showthrea...671846&page=31

[VooDooDaddy]

Originally Posted by GB

We have a whole forum devoted to political b.s. in the basement, you have a political rant, take it to CSM and let the bike talk continue here... comments have been punted.

WTF are you talking about? I don't remember anyone posting up political rants in this thread, or did I miss something?