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Old 06-19-2009, 07:07 AM   #31
NOSIGN
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G'Day Mezo!

If i ever finish my DR project i'll be up for the ride round Oz. I'm subscribed!

I haven't bolted my Safari tank to the frame yet, but i've had it sit where it should be and it does not interfere with my 50mm conventional Marzocchi KTM forks or triples.

!!! I took the DR races and KTM head stem bearings to the bearing shop and the salesman reckons that it's not a good fit and that the bearings will wear quickly! Lukas how are yours holding up? I then set both bearings square and compared the taper, and indeed there is a small angle difference. That means that the ktm bearings will not contact the DR race perfectly.

Torben, was the KTM/ DR stem the same diametre? what model KTM? I'm thinking of pressing the DR stem out and fitting it to the KTM lower clamp - but am unsure if it will fit in the KTM clamp. The KTM stem is 29mm dia, and the DR 30mm dia. However the section pressed into the clamp may be the same, I dunno.

DBM - I have a 1997 KTM EGS (EXC) Ohlins shocker on my DR and it fits well. From memory, you need 2x2mm spacers either side of the top mount to fit the shock snug into the DR frame. I'll post the spacer dimensions on my build up page when I get the chance.
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DR650SE ('97) current project
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Old 06-19-2009, 07:10 AM   #32
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FYI - The KTM head stem bearings are cheaper to buy from the bearing supplier than the special build suzuki bearings.
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CBR900 ('96) the 'ol days
CR250 ('03), 125 ('89), 80 ('85) the 'ol days
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Old 06-19-2009, 07:33 AM   #33
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I still have the original DR races in my frame, probably more than 30.000 kms old, and re-used the old bearings that came with my KTM clamps. Initially I was just going to test them this way for a bit but things got in the way and I have now had them in there for about 10.000 kms without any trouble.

If the DR stem is such a close fit however I would machine it down and use the proper Suzuki bearings. This way you will know 100% that it will never be a problem when you don't need it on a big trip, and you don't have to buy two different bearing kits. I will probably do that next time I have them out as well.

If you do get yours pressed out be so kind and share your findings.
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Old 07-01-2009, 02:13 PM   #34
Gustavo.Ramos
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head

Hi Mezo,

nice project!

My DR's engine is totally tore appart so i'd take this opportunityu to port the head and maybe trimm (or shave it, don't know the exact term) in order to get a bit higher compression.

It seems you have done that, correct?

How much did you "trim" 0.1 cm??
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Old 07-01-2009, 03:09 PM   #35
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Hey hey.
Lookin forward to following your build.
I just got my DR350 a month or so ago and plan on stripping it to it's frame over the winter so between you and a few other threads I hope to learn a some things from your rebuild and few other rebuild threads i've found.

Good luck to you.
-e
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Old 07-05-2009, 07:36 AM   #36
NOSIGN
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rear shock

DBM,

I have fitted a 1997 KTM 300EXC/EGS rear shock to the DR with minimal fuss. Check my build up site frequently.

NOSIGN
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Old 07-08-2009, 07:52 AM   #37
Gustavo.Ramos
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Quote:
Originally Posted by Mezo
"Skimmed" is the word you was looking for, yeah john did this for me im not sure of how many millimeters he took off ? have a read of his 700cc thread

Me thinks your engine could do with the Procycle 725cc kit

Ive just mailed MX-Rob asking if a Keihin 41mm FCR would suit my engine spec, even though he recommends a 39mm.

What carbie are you thinking of running ?

Mezo.
Skimmed! thanks!

For now i'll leave the stock displacement.

Just read the 700cc thread, and seems 1 mm is the way to go. If not, i've ordered 1 extra gasket that may be used to compensate.

About the carb: Mikuni TM40! widely used, widely approved!
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Old 07-15-2009, 02:27 AM   #38
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Keep it coming Mezo. Good stuff!
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Old 07-19-2009, 01:34 AM   #39
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Vince Strang

Theres a guy on the east coast Vince Strang ,Inverell Run a couple of DR ,s in Aus saferi Few years ago couple of times i think .Anyway specialises in modifying parts suspension etc has a few bits that only they get custom made .Heard of him Mezo? Loves to talk all things DR Culd be of some help .Did my rear shock $385 delivered with new spring regas and a bit of a tune of internals kind plush now as they say but firm, I Put emulators in front but did half the job { note to self read instructions }New springs as well oil etc .Good to see boys enjoyed wet ride today Least i didnt throw them of the hillclimb of hopelessness again

dr trebor screwed with this post 07-19-2009 at 01:40 AM
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Old 07-19-2009, 04:28 AM   #40
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It wont fit Mezo so if you give it to me i'll get rid of it for you.

Quote:
Originally Posted by Mezo
Yeah id heard of Vince, one of the first guys sites i read infact, he knows his shit

I have been secretly sussing out the rear end shock solution & heres what i got on fleaby.



Should be here any day, hope it fits

Mezo.
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Old 07-19-2009, 06:28 AM   #41
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Quote:
Originally Posted by Mezo
Yeah id heard of Vince, one of the first guys sites i read infact, he knows his shit

I have been secretly sussing out the rear end shock solution & heres what i got on fleaby.



Should be here any day, hope it fits

Mezo.

Hi Mark
the rear shock looks great tell us how does it feel riding with it?

Yoss
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Old 07-20-2009, 03:59 AM   #42
NOSIGN
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Mezo the bargain hunter!

Looks like i have the same shock. It fits but needs a spacer on top and bottom. I'll post the dimensions when Im next near the bike. I had mine machined. I've still got the old KTM frame, so compared the frame dimensions to make the spacers.

Good buy.
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DR650SE ('97) current project
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CR250 ('03), 125 ('89), 80 ('85) the 'ol days
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Old 07-20-2009, 06:08 AM   #43
Gustavo.Ramos
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shocks

That shock looks rally nice, however, does it have the same length of the stock POS? I believe i have not seen another bike shock as long as the stock suzuki one.

but i'm eager to replace by something else that "really" does the job!
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Old 07-20-2009, 08:10 AM   #44
LukasM
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As I said to Mezo in a PM, I am pretty sure that even the earlier EXC's used a PDS (linkless) rear suspension. The 00 and newer ones do for sure.

So in that case even if it was the correct length, valving and spring weight would very likely have to be changed significantly to work on the DR linkage suspension.

Of course I would be glad to be proven wrong if it works well and gives us a cheap shock alternative.
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Old 07-20-2009, 11:20 AM   #45
Roadracer_Al
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Dang, Mezo, you need to hire yourself out as an eBay Ninja. Fantastic scores on the shocks.

Do you know if these shocks have the PDS mechanism? If you can find a part/model number on the damper body, Ohlins should be able to tell you all about the shock.

PDS is designed to stiffen the damping near the very bottom of the travel to help prevent harsh bottom-outs. If you use it on a rising rate linkage, you might get an excessive amount of damping right at full compression.

I expect that you can disable the PDS by removing the PDS pin. If you decide to keep the PDS, you can add a RaceTech telescoping PDS pin to lengthen and soften the full-compression damping increase.

Also, if the shock is too short, a machinist can create a new bottom yoke that is longer to match the OEM shock.
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