A little Suzuki DR650 build over the winter - Wrist Twisters
 
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post #1 of 39 Old 03-01-2012, 09:32 PM Thread Starter
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A little Suzuki DR650 build over the winter

Hey Everyone! I'm back.....and I'm staying for good!

Well --- as many know.....had a good friend last spring have a horrible crash down south. (yeah, Godzuki....its all your fault....LOL) Decided to take a step back from the 919 for this next year ----- sold off the parts, sold the bike, and walked off with around $6,200.

Seriously. Don't tell the wife.

Godzuki's version of dual-sporting a sportbike.....



Have a cool clip of me on the 919 riding through the Dragon the night after Godzuki's crash....... probably not the best way to take out aggression....but, man.....it sure felt good. You start hearing the 919 at about :35 sec in. The sound of that Arrow exhaust bounching around the woods just sounded amazing...


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post #2 of 39 Old 03-01-2012, 09:37 PM Thread Starter
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I took, half the money and decided to go back to school and work towards a Criminal Justice/Law Enforcement degree (I already have a bunch of college credit to apply) and picked up a used 2007 DR650.

I was lucky enough to find one with some nice add-ons.......decided to dual-sport for the rest of the summer.

The bike came with a TM-40 pumper carb, Clarke 3.9 Gal tank, Renazzco Seat, and a FMF Q2 exhaust can.

Here's the before shot.....



and after.......





After many surgeries and being off work all summer.....Godzuki even showed up for one of his first rides on his new KTM 950 Adventure.

Pretty sure his eyes weren't like this after his crash....I'll have to ask him about it someday.



It was a monumental ride....that weekend! Minus a 45MPH high-side I had on a hard-packed gravel road......

Threw the bike in the garage.....and didn't look at it for 4 weeks. Didn't even wash the bike I was so pissed......

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post #3 of 39 Old 03-01-2012, 09:58 PM Thread Starter
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After a couple years of the DR being riding off-road.....the frame was starting to show signs of chipped paint & rust spots in certain areas. The suspension was in serious need of being rebuilt, and most of the bike needed new bearings......

Decided to leave the engine in (it only have 5,000 miles) and tear into everything else.



The Subframe was in pretty bad shape..... and needed repainting, along with a bunch of other areas.



I made a paint booth in my garage out of painters plastic.....taped it off, found a grey duplicolor paint that matched my frame....and painted away....



Here's the end result..... I also painted a BUNCH of other areas, including the entire down-tube behind the front wheel.


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post #4 of 39 Old 03-01-2012, 10:03 PM Thread Starter
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Next step was to pull the front forks, rear shock, and swingarm.

Swingarm bearings were still good.....2 out of 3 bearings in the lower linkage were frozen......



I pulled apart the rear shock and did a complete teardown...... new 7 wt oil, and an Eibach 1.75 kg/mm rear spring....... compression damping is now usable again.

I don't have pics of this..... I also installed a set of RaceTech Cartridge Emulators in the front forks, along with a set of Eibach .47 kg/mm front springs --- and 10 wt oil.



a shot with the rear shock back in the bike.....



and a shot of the suspension re-installed.....


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post #5 of 39 Old 03-01-2012, 10:06 PM Thread Starter
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the next step was to give the guys a call from WER racing.....and to re-oil my steering damper for road-supermoto use. They recommended 10wt fork oil for better streetability. Oil swap was pretty easy --- there are 2 screws.....and you use an oil bottle/squeegy and push the oil through the unit, then cap off the main bleed hole to keep air out of the system. Messy, but easy.


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post #6 of 39 Old 03-01-2012, 10:09 PM Thread Starter
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I didn't want to pay another $180 for new side plastics, front light shroud was another $75.....so, I sanded down my existing pieces of OEM white, painted them with white Krylon Fuzion, semi-gloss clear coated them, then lightly sanded them down to keep a consistent sheen. Krylon is some pretty impressive stuff.......


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post #7 of 39 Old 03-01-2012, 10:12 PM Thread Starter
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I picked up a new Acerbis universal supemoto fender...... and started the process of installing the WER damper....BTW --- the Previous Owner had the WER damping arm mount welded to the frame.






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post #8 of 39 Old 03-01-2012, 10:15 PM Thread Starter
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Time to pull the exhaust, clean it up and re-install.

This pic is of the FMF PowerBomb header after being re-installed....



and the FMF Q2 ---- had to replace a couple rusty bolts on the canister.


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post #9 of 39 Old 03-01-2012, 10:17 PM Thread Starter
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Then it was time to pull the TM-40 pumper carb and do a cleaning....




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post #10 of 39 Old 03-01-2012, 10:20 PM Thread Starter
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the next step was to install a brand new white plastic tail.

The tail-light BTW is a smaller unit off a DR350...... I have no idea where the PO found the 'Tail Eliminator' with the turn signals tucked up behind the plate bracket. I REALLY like the look of this tail.











and...... plastics finally going back on the bike.


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post #11 of 39 Old 03-01-2012, 10:22 PM Thread Starter
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....time to check the valves before installing the tank and other goodies....also a great time to install a new set of spark plugs......and looks like a bad valve cover seal ---- so, in went a new set.



The DR has an 'Adjustable Tappet' design....loosen the nut, adjust, then re-tighten.


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post #12 of 39 Old 03-01-2012, 10:27 PM Thread Starter
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So ---- at this point...... I was thinking about getting a set of 17's for the DR and making it a full-blown supermoto.

Then I saw this picture..... holy sh&t thats cool...... 19" and a supermoto 17" rear.



So, I had questions as to whether that 19" front would handle the stresses of a track-day and a day at Deal's Gap.......

Then I found this picture, with a 19" front --- LOL, running Metzler Tourane 'Adventure Tires'..... done. I'm sold.


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post #13 of 39 Old 03-01-2012, 10:32 PM Thread Starter
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so..... I stripped down a set of dirt-wheels to the hubs......

and sent the hubs off to Parts, Performance, & Accessories - ProCycle to get relaced...... I ended up going with a 19" 2.50 front and a supermoto 17" 4.25 rear. Bucannon heavy duty spokes, laced to black annozied SUN rims.

This tire choice give a HUGE selection of tires.....stickies, sport-touring, adventure-touring, and full knobs.

I chose to go ---- semi-trackday, touring-street....... Continental Road Attack 2's.

tires are a 110-80-19 front, and a 150-70-17" rear.






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post #14 of 39 Old 03-01-2012, 10:33 PM Thread Starter
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In the process of installing the wheels......I also picked up a SuperBrake fork stabilizer....




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post #15 of 39 Old 03-01-2012, 10:36 PM Thread Starter
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found a couple other 'fun' parts....... I picked up an RSW racing billet upper triple, and a short 'supermoto' kick stand.

what I didn't mention above.....was that went I redid my suspension, I also internally lowered the front/rear for better street/supermoto use. And thus, the needed smaller kick stand.

The Fork brace shown below...... I didn't end up keeping, and sold on the forums..... I choose to use the SuperBrace instead --- its a WAY better and safer design. (the Superbrace sits on TOP of the forks tubes.....the RSW fork brace clamps between the fork tubes)





Heres a picture of the new RSW upper triple.....it also came with 2" far-bar risers...... Very NICE piece.



and yeah --- the large orange front blinkers had to go...... I found this set of K&S clear lens blinkers for $18 a set, via the Tucker Rocky catalog.




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post #16 of 39 Old 03-01-2012, 10:44 PM Thread Starter
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Had some engine cover damage from my high-side crash.....also, its known that the DR's shifter pedal can actually get pushed through the side engine case in a crash.....so, time to fix that. A call to AMR motorcycle products fixed that issue.










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post #17 of 39 Old 03-01-2012, 10:47 PM Thread Starter
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Next step was to install a new set of 520 JT steel strockets....and an RK XW 520 chain.


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post #18 of 39 Old 03-01-2012, 10:49 PM Thread Starter
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and oops.....forgot to mention my 'home-made' axle sliders.

I picked up a set of 100A superhard skateboards wheels...... some rubber hose covered threaded rod later......









I happen to have a couple aluminum spacers off an old set of axle sliders from.....who knows what bike.....LOL. They were perfect to get the sliders away from the side of the fork. Ever better, they had smaller holes than what I needed, so I was able to drill them out to be the perfect fit to the threaded rod.......






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post #19 of 39 Old 03-01-2012, 10:55 PM Thread Starter
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Alright......... time to drop the bike down off the lift and take a look and feel for the suspension......

and yeah ---- ended up replacing the 3.9 GAL Clarke tank for the larger 4.9 GAL IMS tank. This will give me a 200 mile range. I'm keeping the smaller Clarke tank around for the occasional track day.

.....I've tried my best to make sure the chassis of the bike has a slightly forward weight bias..... unlike the rear low --- typical dirt-bike setup. I've achieved this by raising the rear shock by 40mm via. shock mounting (the DR's shock comes with 2 different height mounting eyelets).....and allows me to run the front forks flush with the upper triples.

I still have quite a bit of chassis and suspension tuning and testing to do.


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post #20 of 39 Old 03-01-2012, 10:57 PM Thread Starter
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decided to sell off my original rack....



.....and its back to another Alu-Rack. I liked this rack SOOO much on the 919.

My plan is to find a used large PELICAN case....and bolt it directly to the Alu-Rack with removable wing-nuts.



the Alu-Rack with the Soft-Luggage adapter plate.....a piece I kept from my 919.


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post #21 of 39 Old 03-01-2012, 11:04 PM Thread Starter
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Pretty much thought the bike was done......and a few of you know that I have a weakness for nice Master Cylinders.....

then this 13mm Magura Radial Master Cylinder popped up on SupermotoJunie..... couldn't resist. It even came with a Brembo resevoir & mount bracket.



it was a tight fit behind the hardguard....but I made it work. The handguard had to be shimmed about 10mm outward to make a little more room for the M/C.







To end the M/C install.....most dirt-bikes have their brake line running to the inside front wheel so it won't get caught in the woods/trees, etc. For supermoto and when running larger front wheels....its a better idea to run your line on the outside of the fork leg.

And yeah ---- also picked up a Galfer steel braided brake line...


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post #22 of 39 Old 03-01-2012, 11:05 PM Thread Starter
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so.... there you have it...... my last 2 months of modding.

Stay tuned...... more pictures and tuning to come.


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post #23 of 39 Old 03-02-2012, 12:04 AM
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DANG! I am seriously impressed you did all that in 2 months. Do you even do ANYTHING else?

Very, very impressed. My XR600R is very jealous right now...

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post #24 of 39 Old 03-02-2012, 01:18 AM
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Very cool. I knew you could not leave it alone!

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post #25 of 39 Old 03-02-2012, 01:47 AM
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Very jealous, I think you have more farkles on this one than you did the 9'er. I love the skateboard wheel sliders, they look great. BTW you forgot to mention one mod.



Swing Arm Stickers
Quote:
Originally Posted by arctic954 View Post





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post #26 of 39 Old 03-02-2012, 02:03 AM
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wow....well done!! Thats a lot of work, but it looks great!

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post #27 of 39 Old 03-02-2012, 04:23 AM Thread Starter
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Quote:
Originally Posted by schrock86 View Post

Swing Arm Stickers
Ya know......think I have a left over Penske sticker laying around.....

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post #28 of 39 Old 03-02-2012, 04:49 AM
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Cool build and great write up!

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post #29 of 39 Old 03-02-2012, 07:01 AM
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Looks GREAT.............

I just wish I had a DR650 so I could buy all the add-ons off of it in 6 months when you decide to sell it.

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post #30 of 39 Old 03-02-2012, 07:05 AM
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My DR is jealous. It's been waiting 16 years for that kind of attention!

Sent from my BlackBerry 9650 using Tapatalk

'96 DR650, '01 SV650, '10 Aprilia Tuono 1000R
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post #31 of 39 Old 03-02-2012, 07:21 AM
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You........you are an ARTISTE'!

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post #32 of 39 Old 03-02-2012, 08:20 AM
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Acrtic welcome back! Great build as always, beautiful work and great description and documentation.

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post #33 of 39 Old 03-02-2012, 10:10 AM Thread Starter
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Quote:
Originally Posted by PAULIBIKER View Post
Looks GREAT.............

I just wish I had a DR650 so I could buy all the add-ons off of it in 6 months when you decide to sell it.
Yeah --- no doubt..... the 919 was one of the sweetest bikes I've had....not because it was the most expensive, or the fastest.... it was one of the first bikes that I actually made my own.

For the time being....the plan is to make the DR a long-term keeper, leave it in street trim....and to start saving up for another project. Like the 919 --- the DR's are incredible universal......

I'm heavily leaning towards picking up a plated KTM 200 EXC 2-stroke for my next project. Think it would be a blast in the woods....and with sumo wheels on the karting tracks.

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post #34 of 39 Old 03-02-2012, 11:12 AM
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Welcome back!

Very nice build. Wish I had the space to do work on my bike like that.



[This space for rent]
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post #35 of 39 Old 03-02-2012, 11:12 AM
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Great writeup and pics. Love the skateboard wheels!

Glad you are back.

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post #36 of 39 Old 03-02-2012, 02:44 PM
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Bravo! Love it. ....Needs more white!

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post #37 of 39 Old 03-05-2012, 07:30 PM
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welcome back and great write up

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post #38 of 39 Old 03-05-2012, 09:03 PM
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Cool build! Thanks for taking the time to share.

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post #39 of 39 Old 03-06-2012, 01:10 AM
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[QUOTE=arctic954;
I'm heavily leaning towards picking up a plated KTM 200 EXC 2-stroke for my next project. Think it would be a blast in the woods....and with sumo wheels on the karting tracks.[/QUOTE]

Can heartily recommend the 200 2-stroke idea. After a string of dual-purpose Yamahas and a couple of KDX's, my last off-roader was a Gas-Gas EC200. Absolutely primo woods , forest, single-track bike. A little less hard-edged than the EXC, but in a similar ball-park.

A complete rocket ship once jetted correctly, and ultra-reliable.

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