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Discussion Starter · #1 · (Edited)
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. :whistling:

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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Discussion Starter · #2 · (Edited)
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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Discussion Starter · #3 ·
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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Discussion Starter · #4 · (Edited)
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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Discussion Starter · #5 · (Edited)
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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Discussion Starter · #6 ·
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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Discussion Starter · #8 ·
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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Discussion Starter · #10 ·
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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Discussion Starter · #11 · (Edited)
....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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Discussion Starter · #12 ·
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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Discussion Starter · #13 · (Edited)
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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Discussion Starter · #15 · (Edited)
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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Discussion Starter · #16 ·
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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Discussion Starter · #18 · (Edited)
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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Discussion Starter · #19 · (Edited)
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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Discussion Starter · #20 · (Edited)
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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