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Old 11-18-2011, 06:49 AM   #1
Aquatic OP
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Joined: Dec 2008
Location: Buddina, Sunny Coast, Australia
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2000 F650GS Dakar - Break down and rebuild

After having a Dakar in South Africa and sitting here in Australia for just over 2 years without a bike, I was going insane. And noticeably too. The Mrs said "You need to get another bike!"

So I did!

A 2000 Dakar. Pretty much exactly the same bike that I had back in RSA.
South Africa


Australia

What can I say, I'm a sucker.

Anyway only a couple of weeks after getting the new bike I took a new job and we up and moved from Brisbane south side up to the Sunshine Coast.

All funds that I had put aside had to be reassigned to the move
Oh well, that's life!

So GuS2 has been sitting in the garage tires and battery going flat.

My birthday came along and my wish for a bike lift was granted.


When I got the bike my mind started racing with ideas on farckles and mods.
Unfortunately my current finacial situation does not allow for many of the mods I have in mind, so this will be a very 'Pooratech' rebuild.

Who knows, I might just win the lotto down the line

So this is going to be a very slow process as I will be doing all the work myself.

A big advantage of the new job is all the tools and machines available to use.
CNC Mill
CNC Lathe
CNC Plasma cutter
Guillotine
Press brake
bender
roller
TIG and MIG welding machines
Plenty of Ally, Stainless and Acetyl off cuts
Access to powder coating and laser cutting.

A tinkerers wet dream!


This is what I started with......

On my new bike lift! Thanks Cherie and Jessie ;D

This is the current state of affairs......





Just about all stripped down. Just the engine and wireing harness to pull out.


Like I said this is going to be a time consuming process. Hopefully not too frustrating and very rewarding!


Here goes.........

Aquatic screwed with this post 02-27-2014 at 05:16 AM
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Old 11-18-2011, 07:17 AM   #2
divimon2000
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Location: Lake Champlain, Vermont
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Nice! I may be posing a couple questions your way as I'm doing the same here in the US. Bringing it back to life if you will. Glad I did, lots of loose parts, etc. Have fun mate.
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Old 11-18-2011, 08:15 AM   #3
kubiak
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im watching this build!
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Old 11-18-2011, 04:05 PM   #4
tmotten
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Wow, it seems that rebuilding this bike is getting more and more popular. I'm doing the same things and I'm only just down the road from ya. Good find with the fork upgrade already done.
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Old 11-18-2011, 08:16 PM   #5
GAS GUY
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I'm curious, how many miles are on the bike, and what are your goals ??
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GAS GUY screwed with this post 11-19-2011 at 07:11 AM
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Old 11-19-2011, 12:23 AM   #6
Benjah
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Why you take nice bike apart?
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Old 11-19-2011, 03:29 AM   #7
Aquatic OP
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Quote:
Originally Posted by GAS GUY View Post
I'm curious, how many me miles are on the bike, and what are your goals ??
Not quite 40000kms
And all will be revealed with time
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Old 11-19-2011, 03:30 AM   #8
Aquatic OP
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Quote:
Originally Posted by Benjah View Post
Why you take nice bike apart?
That is who I am!
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Old 11-19-2011, 07:10 AM   #9
GAS GUY
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Quote:
Originally Posted by Aquatic View Post
Not quite 40000kms
And all will be revealed with time
That sounds interesting, good luck, and I look forward to seeing it when its done.
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Old 11-25-2011, 07:28 AM   #10
Aquatic OP
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All stripped down now!

The most together part of the bike is the engine.


I'm thinking I might just make a holding bracket and a stand so I can work on the engine with ease. I'll see what is lying around at work
Things to check:
Valve clearances
Clutch
Water pump gears.
Possible improvements:
New model oil return line replacement
New model 2 piece clutch side cover - if I can find a 2nd hand one some where.

I just need to prep the frame and then I will have all the powder coating parts ready.

Frame, Sub-frame, Swing arm, Engine/Frame bracket, lower twin rail frame, sidestand, foot peg brackets and foot pegs, Crash bars and the other black frame bits will all be powder coated black.

Some issues I picked up on while stripping down:

Swing arm and linkages bearings and bearing races are all fukt!




I went Coastline BMW to get prices for the linkage inner races. "(add expletive here)!" pure extorsion! Cheapest just over $20 and the dearest $35. I didn't dare ask the price of the swing arm bearing races.
MAX BMW in the states is less than half the price.

Cush drive and sprocket holder needs new bearings

The cush drive rubbers are also stuffed. They are split

The bearings are easy enough, I've done that job before.
There is a guy in RSA that makes replacement cush rubbers. They fill the space much better so there is less movement of the rubber in the cavity. And so less wear. $150 for aftermarket and $225 for OEM. Easy choice

The chain roller and swing arm guard need replacing




The bottom neck bearing will need replacing the top one is still 100%

But the nut on the neck was VERY loose. Just about loosened it by hand. Not good

There is a BMW power socket that has been wired into the loom.

I have also installed one of these before and I know this is not standard as the kit comes with a male and female plug as well as a fuse. All just plugs in and no cutting. None of that here. I will have to find out what has bee removed from the loom.
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Old 11-25-2011, 07:32 AM   #11
rc mad
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On some (most?) bikes that power socket is standard fitment, my 06 (with abs and heated grips) has one. I would not be tearing into the loom to remove it! Check with bmw first, they should be able to tell you if it was part of the bike build or not.

Not had my 06 that far apart, yet, I'm getting the urge to rip the abs system off the bike though

Its the sv650's turn first
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rc mad screwed with this post 11-25-2011 at 07:37 AM
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Old 11-25-2011, 07:47 AM   #12
Aquatic OP
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Location: Buddina, Sunny Coast, Australia
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Quote:
Originally Posted by rc mad View Post
On some (most?) bikes that power socket is standard fitment, my 06 (with abs and heated grips) has one. I would not be tearing into the loom to remove it! Check with bmw first, they should be able to tell you if it was part of the bike build or not.

Not had my 06 that far apart, yet, I'm getting the urge to rip the abs system off the bike though

Its the sv650's turn first
Definately not a OEM/standard installation!
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Old 12-11-2011, 01:42 AM   #13
Aquatic OP
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Slow progress

Progress is slow at the moment as I have contracting that is taking up my time. But hopefully the pay day will be big and beneficial to the project.

In the mean time I've come up with and engine stand design to get the donk off the floor and moveable.
I will be adding casters with brakes. To lazy to add them into the design right now.



I also added extra holes so the engine can be rotated side to side if needed



The bosses are away tomorrow and Tuesday. So I should have something to show before the end of the week.

I also received a package from Tmotten. Got some parts to design! Watch this space
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Old 12-12-2011, 10:51 AM   #14
AtlasExp
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Waiting still on my pillow!!!

Maybe in mean while you can post more pics what you all ready did? For engine stand I use car engine stand with couple extra brakets!!! Subscribed an waiting for more!!!!
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Old 12-19-2011, 05:19 AM   #15
Aquatic OP
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Everything ready for powder coating

I don't expect it back in a hurry considering the time of year. But that actually suits me at this moment in time.

All holes are plugged. I just need to straighten the the 2 tabs on the lower frame that hold the bash plate on. And the brake pedal needs straightening.
Also need to make plugs for the neck.

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