DR650 build in Chicago - Page 4

timetravel · 02-17-2011, 04:53 PM

Bike looks fantastic thus far. You're clearly a man with a plan.. And a decent chunk of free time

headlight looks amazing up there

dongie · 02-17-2011, 05:08 PM

Thanks! Time sure is on my side right now :)

EvanADV · 02-18-2011, 09:47 AM

Looks great. Subscribed.

dongie · 02-18-2011, 10:01 AM

A few days ago, I took the shock apart to install the gold valve kit. I decided I'd replace the seal head as well so I had order and wait for it until this morning. Instructions from the Race Tech sheet and ProCycle's website made the rebuild a fairly easy task. One thing I'd like to share is the fact that grinding off the shock shaft peening is not as of a big deal as the instructions try to tell you. The DR's shock doesn't have a rebound adjuster, therefore the shaft is a solid piece of steel which you can easily grind flat to get the nut off.
This will make more sense when you actually get to it. I was all worried and then had a big "aha!" moment when I stopped blindly following the instructions and used my own brain

All you really have to worry about is leaving enough threads left on the shaft for the nut. If you used, let's say, a DRZ shock, then you do have to grind the nut off at an angle.

Here's the shock shaft, with the new seal, gold valve and updated valve stacks:

And here's the shock, fully assembled with a 7.5kg spring, ready to go:

Now I need my back wheel so I can set up the sag and take this bad boy out for a test run!

thumpididump · 02-18-2011, 06:00 PM

nice work !

Cumbacheech · 02-18-2011, 06:05 PM

Quote:

Originally Posted by dongie

Made some progress again today!
New fork guards, new 280mm EBC rotor with a caliper relocation bracket, new Aprilia style mirrors (found on eBay for $15/pair!) and finally a new KLX450 headlight.

Detail of the new brake and guards:

Detail of the headlight. I used the stock DR turn signal mounts for the shroud, the bottom of the headlight is mounted to the bottom triple clamp with a simple alu bracket. I replaced the stock 35w bulb with a 55/60w PIAA ultra white bulb. The beam is a little narrower than the stock headlight but I plan on adding two little external flood lights for night offroading.

The headlight paired up with the YZ450f fender nicely:

WOW

Great Job!!!

matatigres · 02-18-2011, 07:03 PM

Hey buddy you never told me I could see all this here, its looking great man. Funny I has just emailed you about the SM and I take a look in here and theres the new beast. Love it.

dongie · 02-19-2011, 11:14 AM

Quote:

Originally Posted by matatigres

Hey buddy you never told me I could see all this here, its looking great man. Funny I has just emailed you about the SM and I take a look in here and theres the new beast. Love it.

Glad you found me :) Hope Columbia treats you well and you get back soon in one piece!
Emailing you back about the motard right now.

Phreaky Phil · 02-19-2011, 11:21 AM

Have you had a chance to try out the new brake yet ? I enquired at the local bike shop yesterday about an EBC 280mm conversion for the DRZ400 front end on my 650. As usual no stock here in NZ.

dongie · 02-19-2011, 11:51 AM

Quote:

Originally Posted by Phreaky Phil

Have you had a chance to try out the new brake yet ? I enquired at the local bike shop yesterday about an EBC 280mm conversion for the DRZ400 front end on my 650. As usual no stock here in NZ.

I haven't had a chance to ride the bike yet, since I'm still waiting for the rear wheel. I think that there won't much difference in stopping power between the EBC 280 rotor and the stock 290mm DR rotor. You might have better luck finding a 320mm rotor kit for the DRZ/RM mount. I tried to run that on my DRZ a few years back and felt like it was too grabby in dirt. If you mostly run your DR on road, the 320 rotor might actually be better.

Here's my old dirt setup with the 320 rotor:

dongie · 02-19-2011, 11:58 AM

Quote:

Originally Posted by Phreaky Phil

Have you had a chance to try out the new brake yet ? I enquired at the local bike shop yesterday about an EBC 280mm conversion for the DRZ400 front end on my 650. As usual no stock here in NZ.

They still have one left. I could always buy it and send it to you if you want to pay for shipping to NZ..

http://cgi.ebay.com/ebaymotors/EBC-O...#ht_1087wt_941

Phreaky Phil · 02-19-2011, 01:43 PM

Quote:

Originally Posted by dongie

They still have one left. I could always buy it and send it to you if you want to pay for shipping to NZ..

http://cgi.ebay.com/ebaymotors/EBC-O...#ht_1087wt_941

Thanks for the offer, I might have to leave it for a while. Funds are a bit limited for a few weeks, I just ordered a Procycle 780 kit this week and am off for a weeks riding next week.
Your bikes looking sharp, the headlight suits it.

dongie · 02-22-2011, 07:39 PM

Finally got my back wheel from Buchanan today! I think I broke my tire mounting time record tonight

There's still a few things that will go on the bike (skidplate, windshield etc.) but I had to take a quick snap of the bike anyway. I think it's turning out nice

rokklym · 02-22-2011, 08:12 PM

Sweet!

jenx · 02-22-2011, 09:45 PM

Nice one!! Maybe Zook will look at this when they update the dr.

02-18-2011, 09:47 AM	#48
EvanADV Big Bearded Boy Joined: Jul 2010 Location: Joplor, NC Oddometer: 1,065	Looks great. Subscribed. __________________ Current: '07 B1250. Former Steeds: '99 DR650, '02 DR650, '09 DL650 First Trip on 2 Wheels. 10,000 miles. 21 years old.

02-18-2011, 06:00 PM	#50
thumpididump MacGyver Joined: Jul 2009 Location: Canada Oddometer: 1,972	nice work ! __________________ _______________ "You can't put the shit back in the donkey." - Tony Soprano FYYFF

02-18-2011, 07:03 PM	#52
matatigres endless summer Joined: Feb 2010 Location: Chicago Oddometer: 91	Nice work!!! Hey buddy you never told me I could see all this here, its looking great man. Funny I has just emailed you about the SM and I take a look in here and theres the new beast. Love it. __________________

02-22-2011, 08:12 PM	#59
rokklym one man wolfpack Joined: Nov 2004 Location: Westby Wisconsin Oddometer: 4,294	Sweet! __________________ Check out the Blog! MotoGraphic MotoGraphic Tumblr Chad Berger KTM950ADV, DR650 Lone Wolf Expeditions

02-22-2011, 09:45 PM	#60
jenx misadventurer Joined: Oct 2007 Location: Johannesburg, South Africa Oddometer: 552	Nice one!! Maybe Zook will look at this when they update the dr. __________________ Plans to get my own piece of paradise (comments and advice welcome): http://mountain2c.wordpress.com/

02-17-2011, 04:53 PM	#46
timetravel Adventurer Joined: May 2009 Location: Chicago Oddometer: 13	Bike looks fantastic thus far. You're clearly a man with a plan.. And a decent chunk of free time headlight looks amazing up there

02-17-2011, 05:08 PM	#47
dongie ^OP Brraaap Joined: Dec 2010 Location: Chicago Oddometer: 241	Thanks! Time sure is on my side right now :)

02-18-2011, 10:01 AM	#49
dongie ^OP Brraaap Joined: Dec 2010 Location: Chicago Oddometer: 241	A few days ago, I took the shock apart to install the gold valve kit. I decided I'd replace the seal head as well so I had order and wait for it until this morning. Instructions from the Race Tech sheet and ProCycle's website made the rebuild a fairly easy task. One thing I'd like to share is the fact that grinding off the shock shaft peening is not as of a big deal as the instructions try to tell you. The DR's shock doesn't have a rebound adjuster, therefore the shaft is a solid piece of steel which you can easily grind flat to get the nut off. This will make more sense when you actually get to it. I was all worried and then had a big "aha!" moment when I stopped blindly following the instructions and used my own brain All you really have to worry about is leaving enough threads left on the shaft for the nut. If you used, let's say, a DRZ shock, then you do have to grind the nut off at an angle. Here's the shock shaft, with the new seal, gold valve and updated valve stacks: And here's the shock, fully assembled with a 7.5kg spring, ready to go: Now I need my back wheel so I can set up the sag and take this bad boy out for a test run!

02-19-2011, 11:21 AM	#54
Phreaky Phil Beastly Adventurer Joined: Mar 2006 Location: NEW ZEALAND Oddometer: 1,169	Have you had a chance to try out the new brake yet ? I enquired at the local bike shop yesterday about an EBC 280mm conversion for the DRZ400 front end on my 650. As usual no stock here in NZ.

02-22-2011, 07:39 PM	#58
dongie ^OP Brraaap Joined: Dec 2010 Location: Chicago Oddometer: 241	Finally got my back wheel from Buchanan today! I think I broke my tire mounting time record tonight There's still a few things that will go on the bike (skidplate, windshield etc.) but I had to take a quick snap of the bike anyway. I think it's turning out nice

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