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Old 03-10-2015, 07:02 PM   #1
boardrider247 OP
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Joined: Aug 2008
Location: Forest Lake, mn
Oddometer: 766
Do it ALL DR 650

To begin I started working through the logistics of this project several years ago. At that time I decided I was going to build a DR 650 with 17" wheels to commute and play on, as well as keeping a set of 21/17 wheels for off road duty. I had chose a DR for something reliable, low maintenance that could cruise highway speeds. And of course having a million of them on the road with a huge aftermarket wasn't a bad thing.

I began purchasing the necessary bearings and parts to fit GS 500 wheels and ended up getting a screaming deal on a KTM 640e. So the DR project was put on hold. Next came a KTM 950a. DR still on hold.

Now finally 3 years later I actually own a DR and will make this project happen.
Then 3 years and 1 week later I now own 2 DR's Project just got a little more interesting

First post I will lay out my intensions and introduce the victims......

The end result will include
-17" wheels (GS 500)
-Updated pumper carb
-GSXR exhaust
-DRZ 400 forks
-Updated rear shock
-Larger tank
-Better seat
-Large amount of scope creep

The first bike I bought was a 96'. Unknown miles it has had a rough life, but had a good assortment of aftermarket parts. IMS tank, Pro Cycle seat, HDB handgaurds, wolf man tail rack as well as a couple other nice to have extras.

IMG_20150212_155935 by boardrider247, on Flickr

When I picked up the bike it was -15 outside and it wouldn't start. No surprise there, but after bringing it home to the heated garage it still would not start A quick carb clean and everything was as it should be. After going over everything it was obvious the PO should have had his tools taken away from him. But at some point someone did love this bike so I believed there to be some hope. It will need a new wiring harness and a couple other small fixes overall though she is solid.

After buying the 96' I never did pull down my CL wanted ad. No particular reason I just was being lazy and didn't remove it. Literally 24 hours after bringing home the 96' I received a email from a guy with a crashed 05' 15k miles. I didn't put much though to it but asked for pics and a price. Low and behold the pics looked good, the price was low and I had to have it

IMG_20150224_181832 by boardrider247, on Flickr

My original intension was to use the 96' as a parts donor for the 05'. But through some luck in the flea market I was able to come up with enough parts to rebuild the 05' for under $250. So the 96' will donate her aftermarket parts, get a new wiring harness and the plastic's from the 05' then be sold off to fund the 05' build. I have been keeping the dude in the little brown shorts very busy with parts coming from ebay and FM purchases. Once I have the 96' out of the way the fun parts from Pro Cycle will be on their way. With the unseasonably warm weather I expect some good progress this week with lots more pics.
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Old 03-12-2015, 05:55 PM   #2
Yella DR
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Do not visit Procycles web site.
Do not look at the 790 kit.
...I ...must....not....order....

mxrobs FCR39 kit changes everything along with a Aus. made mid pipe bolted to a nicely tucked 'busa pipe.
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Old 03-12-2015, 07:59 PM   #3
sonic reducer
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What will you do to the suspension?
I'm in a similar boat, just picked up a pretty decently modded DR with 22k on the clock for a good price. Going the 1 bike route, selling my 525 and my litrebike to get back to basics for a while. Spent a few years kicking myself for getting rid of my last DR.
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Old 03-13-2015, 04:34 AM   #4
boardrider247 OP
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Location: Forest Lake, mn
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Quote:
Originally Posted by Yella DR View Post
Do not visit Procycles web site.
Do not look at the 790 kit.
...I ...must....not....order....

mxrobs FCR39 kit changes everything along with a Aus. made mid pipe bolted to a nicely tucked 'busa pipe.
A FCR is on the list of things to do for sure. I found mxrobs webpage but didn't see any mention of selling a kit. Got a link
I was given an entire gsxr exhaust and bought some stainless tubing, thinking I will build my own midpipe and use that muffler. It is a basically brand new take off from a 750.

Quote:
Originally Posted by sonic reducer View Post
What will you do to the suspension?
Been thinking a lot about that the last couple days. For the front I already have a set of 01 DRZ cartridge forks and triple clamps which bolt on. So that is what I will use. Been buying the necessary extras off ebay to finish that up (brake,wheel,spacers ect).

The rear is a bit more of a head scratcher. Originally I had planned on a DRZ shock. Not sure it is worth the hassle though.
-$100 used shock
-$120 new spring
-$150 have the shock rebuilt
-$50 misc bearing ect to make it all go together

Best case I may be able to get a DRZ shock into the bike for $300-350. A brand new cogent Mohave is $650. This may be one case where I just concede and spend a few extra bux to get the bike back together sooner. And to avoid the hassle of tuning a rear shock that wasn't meant for the bike.

Another option I just came across is a ohlins rear shock from a LC4 bike. This is very appealing. I like all of the ohlins bikes I have ridden and the LC4 is already closer to the same weight as a DR so tuning should be in the ballpark already.
Still researching this option but I may just dive in and buy a shock if one comes up.
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Old 03-13-2015, 06:16 AM   #5
Yella DR
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I contacted Rob and went from there. He needs your location and such for proper jetting. Here's mine

https://www.flickr.com/photos/130616...3/16380915037/

I used this with the 7.5 spring. You get access to set up your valving to the type of riding you do. I was honest and realistic with my needs- no complaints at all. Can now make progress on wash board roads now that I previously could not.
Easy install but had to drop $20. for local nitrogen recharge...

https://www.procycle.us/bikepages/dr...-shockdr650-xx

About to begin

https://www.flickr.com/photos/130616...3/16608812165/

That mid pipe is cozy in there, and you'll need the proper flange.

Why can't I access my Flikr acct...wtf...


Edit- Got on the laptop and tried these links - muffler pic was day of install.



https://www.flickr.com/photos/130616...3/16423044119/
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Yella DR screwed with this post 03-13-2015 at 08:05 AM
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Old 03-13-2015, 08:11 PM   #6
villageidiot
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Location: Orange County, CA
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Quote:
Originally Posted by boardrider247 View Post


The rear is a bit more of a head scratcher. Originally I had planned on a DRZ shock. Not sure it is worth the hassle though.
-$100 used shock
-$120 new spring
-$150 have the shock rebuilt
-$50 misc bearing ect to make it all go together

Best case I may be able to get a DRZ shock into the bike for $300-350. A brand new cogent Mohave is $650. This may be one case where I just concede and spend a few extra bux to get the bike back together sooner. And to avoid the hassle of tuning a rear shock that wasn't meant for the bike.
send a stock shock to cogent, and have him rebuild it and coat it, and do the upgrade shock shaft. its 100+ cheaper than the cheapest mohave, and bolts right back in to the frame with no headache. i did it to mine, and am A+ glad i did. no complaints!

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Old 03-14-2015, 06:49 AM   #7
boardrider247 OP
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Location: Forest Lake, mn
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Quote:
Originally Posted by villageidiot View Post
send a stock shock to cogent, and have him rebuild it and coat it, and do the upgrade shock shaft. its 100+ cheaper than the cheapest mohave, and bolts right back in to the frame with no headache. i did it to mine, and am A+ glad i did. no complaints!
Thanks I'll look into it. Going to send Cogent a email today and go over my options. I think I am going to put a stop to any spending on this project until I am able to weld up the case on the 05 bike and make sure it runs OK.
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Old 03-14-2015, 07:21 AM   #8
boardrider247 OP
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The most boring project update ever!!!!

I will forewarn you this update is essentially just putting a bike back to stock. There is not much interesting to see here other then a few WTF previous owner "modifications". You have been warned

After verifying that is ran.
I started tear down of the 96 so I could clean all of the mud off of it and remove the wiring harness.
IMG_20150218_160948 by boardrider247, on Flickr

IMG_20150218_175036 by boardrider247, on Flickr

IMG_20150225_190337 by boardrider247, on Flickr

IMG_20150225_191418 by boardrider247, on Flickr

IMG_20150225_191428 by boardrider247, on Flickr

Rolled her outside and washed for 3-4 hours. Seriously.
IMG_20150312_100647 by boardrider247, on Flickr

IMG_20150312_135347 by boardrider247, on Flickr

IMG_20150312_135357 by boardrider247, on Flickr

Bolted a new OEM exhaust on that came with the 05. The exhaust on the 96 had some welds on it which were rather scary looking. No idea why it would have needed welding??
IMG_20150312_144254 by boardrider247, on Flickr

And laid out the new wiring harness to swap over.
IMG_20150313_084435 by boardrider247, on Flickr

This is why I felt the need for a new harness. Let's play who can count all the splices.
IMG_20150313_084456 by boardrider247, on Flickr

IMG_20150313_084512 by boardrider247, on Flickr

IMG_20150313_084553 by boardrider247, on Flickr

IMG_20150313_154539 by boardrider247, on Flickr

Before I started to change out the wiring harness I started the bike up and ran it to be sure everything was still good to go. No surprises right?

Well after the new harness is in bike won't start
Went over all my work twice. Messed around with the coil connections. Finally went through the testing procedure in the manual and came up with a bad CDI. I thought no fucking way did the CDI go bad in the last hour but swapped the box over from the 05 bike and sure as shit it fired right up.

Other than that drama it was a rather uninteresting day of swapping parts from the 05 bike to the 96.

Suzuki could have spent a couple extra cents to actually put some grease on these bearings. This is straight out of the 05.
IMG_20150313_090636 by boardrider247, on Flickr

IMG_20150313_092154 by boardrider247, on Flickr

IMG_20150313_100223 by boardrider247, on Flickr

IMG_20150313_100234 by boardrider247, on Flickr

IMG_20150313_102801 by boardrider247, on Flickr

IMG_20150313_144830 by boardrider247, on Flickr

The PO of the 05 bike had generously painted the body work. Twice. So I had to take some stripper to it and clean all that crap off.
IMG_20150313_155349 by boardrider247, on Flickr

He also had a interesting way of holding the headlight in.
IMG_20150313_154919 by boardrider247, on Flickr

As she sits for now.
IMG_20150313_163109 by boardrider247, on Flickr

I did take her for a little ride to make sure the transmission gears all work. Everything seems to be fantastic. Despite the scary electrical work I think this bike was well take care of.

This is what the 05 looks like at the end of the day.
IMG_20150313_163043 by boardrider247, on Flickr

Still left to finish on the 96
-Change oil
-Adjust valves
-Mount headlight (waiting on parts)

Then I will ride her a couple days to make sure everything is ready to go and put her up for sale. That money can then be put towards building the 05 where the real fun will begin
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Old 03-17-2015, 04:07 PM   #9
boardrider247 OP
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96 is basically finished.
IMG_20150317_165850 by boardrider247, on Flickr

Just waiting for a new owner

I started to pound some bearings for the GS wheels last night but didn't make it far. I need to get the wheels mocked up and some measurements taken for spacers then find someone with a lathe kind enough to give me a hand making them.

Progress pics to follow.After St. Patty's day
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Old 03-18-2015, 06:35 AM   #10
tominboise
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Nicely done on the '96, even if it was only raising it from the dead.

Waiting on the '05 build.

Sometimes long for dumping the three i have now and going the way you are headed....
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Old 03-18-2015, 05:27 PM   #11
Scubawerx
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Waiting on a new owner? You selling?
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Old 03-18-2015, 05:38 PM   #12
boardrider247 OP
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Quote:
Originally Posted by Scubawerx View Post
Waiting on a new owner? You selling?
Already sold. Can't believe how quick it went. Had 4 buyers waiting cash in hand after less then a day.
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Old 03-18-2015, 05:40 PM   #13
boardrider247 OP
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Played around fitting up the rear GS wheel today.
No pics as I was cut short when I found out mice have made a home inside the spindle housing on my drill press
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Old 03-20-2015, 12:53 PM   #14
boardrider247 OP
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I was able to get the DRZ forks on with new steering bearings in.
All of my specialty tools are from China. NO they are not the best tools, but having the right tool for the job even if it is cheap is still better then trying to make due with the wrong tool.
IMG_20150319_173525 by boardrider247, on Flickr

IMG_20150319_175006 by boardrider247, on Flickr

IMG_20150319_180544 by boardrider247, on Flickr

The steering neck on the DR is a touch longer then on the DRZ. But I took some measurements and I still have full thread engagement on the top nut so I don't see any need for changing the steering stems.

I'm not going to run the mechanical speedo so I ordered two of the left side wheel spacers.
IMG_20150319_180552 by boardrider247, on Flickr

Here is the section of engine case I need to weld up.
IMG_20150319_180644 by boardrider247, on Flickr

There was also a bolt for the stator cover which was broke off. I extracted it

IMG_20150319_180711 by boardrider247, on Flickr

IMG_20150319_181857 by boardrider247, on Flickr

Once I have a tire mounted on the front wheel I can roll the bike over to my welding garage and try to fix the case. Maybe if all goes well she will be running again by the end of the weekend.
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Old 03-20-2015, 07:38 PM   #15
brownvv
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you will like the drz forks. they are a nice upgrade. I still have the stock springs in them and they are way less squishy than the old forks
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