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Old 01-10-2012, 03:27 AM   #1
MartinPetren OP
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DR650 Restoration

Hello, this is a thread about my ongoing restoration of my DR. I never meant to do a thread about it, but the official Dakar thread is just taking too much time of my hands.. time to do something else aswell! F5

Every restoration thread needs a before picture, and here it is:



As you can see it's quite rusty and has lost some of it's shine. There is also alot of small things that need to be repaired/replaced.

The frame is going to get powdercoated black as well as a few other things.. So first of all a complete disassembly was done!



This is how far I got during day 1.



Day 2 and everything is stacked up in the basement. This is where I will keep the parts during the process, and as we go along I will re-assemble it in the garage shown in the second picture above.

Oh, I also cleaned up the garage when the bike was dis-assambled. That's what I went up doing on day 3.

Today is day 4 of restoration and I will start cleaning up the frame for powdercoating. If there's time I will start looking at the swingarm that is going to be freshened up a bit.

But before I start doing that, It's time to see how Despres is doing in the Dakar F5-out.

edit: Thought I could share some of my plans:

New parts:

- TKC80 Front and Rear [check]
- Black frame [check]
- Black fork gaitors [check]
- Crash bars
- New hand protectors, old one's broke [check]
- Full service on clutch, and 10% stronger springs [check]
- New handlebar [check]
- New chain slider, both on swingarm and lower [check]
- New chain
- New grips [check]
(- new springs to fork ) we'll see how far my budget reaches...
- New blinkers [check]

Cleaning up:

- All plastic [check]
- Tank, inside as well.
- Swing [check]
- Wheels [check]
- Engine [check]

Parts I'll paint myself:

- Linkage ( maybe.. ) [check]
- Sidestand [check]
- Kicker [check]
- Steering crown
- Pipe ( not the slip-on part ) [check]
- Pegs [check]

Next update will contatin more pictures of process!
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Old 01-10-2012, 03:54 AM   #2
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I'm in......
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Old 01-10-2012, 03:58 AM   #3
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Originally Posted by cyclewizard View Post
I'm in......
This could take a while, be sure to bring a lot of popcorn! As always with me about a million more stuff than planned will be done, way over my budget
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Old 01-10-2012, 04:03 AM   #4
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This could take a while, be sure to bring a lot of popcorn! As always with me about a million more stuff than planned will be done, way over my budget
Haha... I know what your saying once you dig into her you can't stop, but the end result is worth it..
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Old 01-10-2012, 04:14 AM   #5
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I made a to do list before starting on the bike, all I can say is that it has expanded. Most important is to not let my girlfriend find out
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Old 01-10-2012, 05:11 AM   #6
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I made a to do list before starting on the bike, all I can say is that it has expanded. Most important is to not let my girlfriend find out

It's easier to ask for forgiveness than permission..
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Old 01-10-2012, 05:20 AM   #7
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This is not really a good idea.

I did the same on a bike a few years ago (1969 Triumph Daytona) and because it looked so nice (better then new), I never rode it in the dirt again, got tired of just street riding and sold it.

Once its all new looking, are you going to be able to ride it right into a mud hole?
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Old 01-10-2012, 05:33 AM   #8
MartinPetren OP
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This is not really a good idea.

I did the same on a bike a few years ago (1969 Triumph Daytona) and because it looked so nice (better then new), I never rode it in the dirt again, got tired of just street riding and sold it.

Once its all new looking, are you going to be able to ride it right into a mud hole?
I am sooo looking forward to get that bike back into the mud

This year (2011..) has been so awesome that I can't wait for next riding season, the reason of restoration is that I felt bad for all the abuse I've done to it. So I'm fixing her up just so that I feel better next time I'll abuse her

As a matter of fact my last ride with her was in a local sandpit, and there's a step up there which I tried a couple of times but couldn't get enough speed with my worn tires. So I promised my self that my first ride after the restoration will be in that sandpit.
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Old 01-10-2012, 12:25 PM   #9
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Today which is day 4, I think, of restoration has been eventful.

I bought some new supplies for the process:

- Brake cleaner
- Degreaser ( in the yellow bag )
- Sandpaper
- Vaseline spray ( to put on finished parts, protects against corrosion and oxidation )
- Hammerite spray paint, smooth finish
- Thermalpaint, for exhaust etc.
- Some sponges and a brush
- Autosol, for a nice finish.
- Clear coater


After inspecting what I've bought I then proceeded working. First off was the frame that needed to be degreased and clean in general, it came out pretty good. You can see how rusty it is.

Unfortunately I discovered a small crack in frame. Just in front of the sidestand, my theory is that water has been standing there causing it to rust from the inside. So that have to be welded before sending it to be powder coated.

After being done with the frame, I began cleaning the rear suspension. It was seriously dirty! But cleaned it up a bit and put a layer of vaseline spray on it.

Last of all I began with the swing. It was not looking nice so I decided to polish it. I'm already sick of grinding it down with sandpaper.. But the outcome will be good. Just have to be patient for tomorrow, then I'm going to finish it. (hopefully)

Now it's time to watch the Dakar highlights from yesterday!
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Old 01-10-2012, 05:40 PM   #10
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very nice

check out the pre 96 dr thread

keep up the go work
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Old 01-10-2012, 07:11 PM   #11
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Originally Posted by MartinPetren View Post
Unfortunately I discovered a small crack in frame. Just in front of the sidestand, my theory is that water has been standing there causing it to rust from the inside. So that have to be welded before sending it to be powder coated.
Martin,

That is a common problem. This is my 90 model:







I was going to weld it myself, but figured it would be better if someone TIG welded it. The welder said there was still a lot of metal left and patches should work ok. Before welding, use compressed air to blow most of the loose rust out. Your frame should have a drain hole on each side of the frame near where the rear fender bolts on. Blow the air through these holes and it will come out of the rust holes.

I drilled a 3mm drain hole in each side (through the patches) and after the frame was painted I used a spray can of rust killer/sealer and gave it a good soaking. Roll the frame a few times to help spread it around.

Good luck with the project!

Cheers,
David.
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Old 01-10-2012, 11:19 PM   #12
MartinPetren OP
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Martin,

That is a common problem. This is my 90 model:







I was going to weld it myself, but figured it would be better if someone TIG welded it. The welder said there was still a lot of metal left and patches should work ok. Before welding, use compressed air to blow most of the loose rust out. Your frame should have a drain hole on each side of the frame near where the rear fender bolts on. Blow the air through these holes and it will come out of the rust holes.

I drilled a 3mm drain hole in each side (through the patches) and after the frame was painted I used a spray can of rust killer/sealer and gave it a good soaking. Roll the frame a few times to help spread it around.

Good luck with the project!

Cheers,
David.
Yours was really looking horrible! I'm glad I found mine in good time. Do you live close to the ocean? I've seen a few DR's that has been completely ruined because of the salt in the air.

I'm checking with a friend to see if he's having a TIG weld, my welding machine is definitely not usable.

My thought was exactly as you've done, patch it and then drill some draining holes through the patches. Did not think of the rust sealer though. It's for sure worth a try!

Oh and btw, do you by any chance have an after pic?

Thanks,
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Old 01-10-2012, 11:20 PM   #13
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very nice

check out the pre 96 dr thread

keep up the go work
I'm a regular lurker in that thread

Thanks,
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Old 01-10-2012, 11:32 PM   #14
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First of all, I'm so damn tired right now.. Stayed up all night planning all the purchases for this project! Not much was ordered but some parts from the Hessler shop at least.


Notice that I ended up not buying the crash bars, they'll just have to wait. I think I'll order them as the last part for the project, as a nice little touch up in the very end.

Now I have to wait for the parts to arrive, It's only from Germany so it shouldn't take long.

Today's plan is:

- After work go to my local bike shop and pic up a new air filter.
- Order new brake pads and some new rear indicators, old one broke during my last ride.
- If there's time I'll continue on the swing polishing.

Now time for work, and then some serious F5:ing in the Dakar thread

Over and out!
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Old 01-11-2012, 01:18 PM   #15
MartinPetren OP
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Short update.

Today I picked up an air filter that my father order for me as a christmas gift. Took a while to receive it, not that it really matters at the moment, though..

It's an OEM filter.



When I came home I made some delicious pancakes and later I started working on cleaning the carburator. There are two reasons why I bother to clean it on the inside and the outside:

1. I really don't think anyone before me took their time to do so.
2. My last air filter went through it. It's my bad for not changing it in time.. But I suspect my combustion chamber thought it tasted good as there is no sign of there. Though I did find some traces inside of the carburator! Look to the right at the slider.



I cleaned it all up with some brake cleaner and I'm going to put a protective layer of vaseline on it when I get back to the workshop/garage.



A few more things:
- I have found someone to weld the frame for me
- Hessler shop replied to me with a tracing number, order has been dispatched
- The frame is going to be left at the powder coater on Tuesday next week


Looking forward to next update, hopefully I will show you the result of the polishing on the swing.
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