REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Bikes Motorcycles, S x S's, Tractors, and Mowers => Topic started by: Flyin6 on September 15, 2014, 03:51:35 PM

Title: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2014, 03:51:35 PM
Let's get this build started.
So, as a part of an individual survival plan a motor-cross or a dual-sport bike is a great part. Capable of moving across just about any terrain it could put you a long ways from danger in a short period of time, and all with a very low signature. Learn to ride it at night and maybe even with night vision goggles, and you could practically move without being noticed.
Now, this DR is going to fulfill a slightly different and unique role.

I consider it as a part of a system. I plan to carry this bike on the back of SquareD, the modified early Dodge truck, along with a trailer so as to form a survival system.

Consider an extended travel away from danger. The Dodge, equipped with in excess of 100 gallons of fuel could feasibly remain operational for a month or more depending on how much it is used. A scenario might to be to get away from, say an urban area, but just far enough to be safe for a time, while you access the situation, and indeed allow the situation to develop.

A city will ignite into chaos fairly quickly as infrastructure and police/government collapses. So by getting yourself more than a couple days walking distance away, you have literally increased your chances of survival many fold. But move around too much and you simply place yourself under observation of more and more areas (Read: People!)

So in this imaginary scenario, everything is imploding, but you got out with what you have packed. With the survival system of truck/trailer/bike and lots of food, shelter, and water purification, you have moved to an isolated spot and set up a bivouac.

After establishing that you have built in some good cammo and are reasonably sure that you won't get many unexpected visits. next you might want to start to check out the surrounding area. Where are the people? Where are the choke points? Where are possible fuel or food collection areas. You could do this in one of several ways. You could lace up the boots and go for several days of hiking, bedding down tactically each night, or better yet, bed down during the day, and move at night. If you had some aerial observation device, you could employ that. If you had a low signature quad, UTV, or motorcycle, well just jump on it.

This is why the DR-650 project was given life and why it is going to be a part of the survival system starting with SquareD.\\THis bike build will look a lot like the outfitting of a world class adventure touring bike with some exceptions or additions.
It will have:
1. A better suspension
2. More power
3. protection for both the engine and the rider
4. Have a weapon mount
5. Be night vision capable
6. Be built on a low-observable concept (Read: Camouflaged)
7. Have a very long range or endurance
8. Carry everything I will need to self sustain for weeks if necessary
9. Be made simple and reliable
10. Feature GPS, communications equipment, and have a laptop computer to record information and possibly control the helicopter/camera system which will be roof mounted onto the truck.

After looking at many candidate bikes, the ultra simple and reliable design of the Suzuki was selected. It is air cooled, proven over decades, and in fact remains largely unchanged since it'd introduction in the mid 1990's. It is simple and rugged, and has a reputation amongst its riders as being nearly bulletproof.

With the decision made, a hunt on Craigslist quickly identified the candidate bike. A 2012 model with less than 2500 miles and already boasting some killer upgrades. The owner was contacted, a price negotiated, and I made the purchase.

So, without further adieu here is the bike as it existed the day I purchased it:
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:32:42 PM
More:
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:34:40 PM
So stock!!!!!!!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:35:42 PM
But already has some great front forks from a MX bike
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:37:48 PM
And a big brake kit! Along with guards for the inverted forks!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:40:16 PM
Some kind of super cool handlebars
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:41:25 PM
The Voyager GPS speedo/timer/computer thing...and the padding on the bars
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:43:15 PM
Pre installed bo-bo
Heck I just might leave it there...it still works!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 04:45:01 PM
Nope, that's not my license plate.

Just an aft view of the bike before the mods begin...

For a purchase price of $3350, an excellent buy and starting point me thinks!
Title: Re: DR-650 Build Thread
Post by: OVERWATCH_09 on September 15, 2014, 05:47:37 PM
What are the plans for mounting on the truck? Standard hitch mounted rack or something else up your sleeve?
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 15, 2014, 07:17:05 PM
What are the plans for mounting on the truck? Standard hitch mounted rack or something else up your sleeve?

Definitely something else up me sleeves

Picture a 4' X 4" square tube hinged with a gigantic hinge, more like you'd find on a track loader affixed to the left side. It rests on a support on the right side of the bumper and is pinned vertically to retain it in position with a 1" through pin
Everything is close tolerance (No-slop) and has zerks
The hinge on the left side is multi-axis
Below the box tubing is a hydraulic jack, one end affixed to the hinge, the other to the section of 4 X 4
The top of the bar has fixtures to guide and capture the bike. The wheels will drop into large "Catches, through which a series of nylon protrude and affix to the bike in several locations. Those straps anchor in a lever affair that simply pushes down to lock the bike into place.

To deploy the bike: Lift up the lock pin. Rotate the bike left until it presents at about a 30 degree angle away from and relative to the Cl of the vehicle. Turn a valve to release hydraulic pressure and the end of the steel tube settles to the ground.
Release the straps in a predetermined sequence, then roll off the bike and it's ready to use
Title: Re: DR-650 Build Thread
Post by: JR on September 16, 2014, 01:32:09 AM
Looking good Don.

That setup for the carrier works good. I made one just like that about 20 years ago. Front had a rake to hold the front tire, rear did the same but also folded down for loading. I still found I needed a brace in the center for driving around though. Was on my 77 Jimmy lifted 6 inches with 36 inch Mickeys.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 16, 2014, 10:33:13 AM
Looking good Don.

That setup for the carrier works good. I made one just like that about 20 years ago. Front had a rake to hold the front tire, rear did the same but also folded down for loading. I still found I needed a brace in the center for driving around though. Was on my 77 Jimmy lifted 6 inches with 36 inch Mickeys.

Cool JR
I plan to use 4" X 4" X .250" tubing
Plan to make the hinge out of some pins off my Case (28,000lb) Track Loader.
I don't think that will flex, and it will be supported and captured on either end
Think that will work?
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 16, 2014, 10:39:25 AM
JR,
And question for ya
I am about to acquire one of thise 6.6 gallon Aceribus (or however you spell that name) fuel tanks
They tell me you can't paint it or put decals on it, because it seeps fumes from all over!
WHHHAAAAT?
Anyway, that is just a challenge.
I am going to paint it and decal it up with the cammo wrap
So me is thinkin' out loud
I'm thinking I spray the outer surface with an adhesion promoter first, then a primer, then a coat of paint. Perhaps even run some sort of sealant all around the inside of the tank to prevent this pesky migration of fuel molecules.
Concerns: Interior lines stuff flakes off and clogs the petcock/filter and we have sudden stoppage. Secondly, my paint and wrap falls off the tank just when and while some Harley guys are ridiculing the "Pretty Little" Jap bike...Not as a Harley owner, that I have ever done that....just sayin...
Title: Re: DR-650 Build Thread
Post by: JR on September 16, 2014, 11:54:40 PM
Order the color you want for that part. Trick is from what I have read i to paint and decal before you put gas in it. You need to use the porus decals.

I have a black tank,,,,,,,,,,,,,,,,,
Title: Re: DR-650 Build Thread
Post by: JR on September 16, 2014, 11:56:32 PM
http://justgastanks.com/product_info.php?products_id=2716&cPath=115&m1track=googlebase&utm_source=googlebase&utm_medium=cse&utm_campaign=export_feed&gclid=CjwKEAjwv9-gBRD5ofn2jd2N0UUSJACcdilsIZQLqPSBXsUF4TgJt3ntClslJy_vzz0aQECtIRcV7hoCbhjw_wcB&osCsid=1c48a4a0fadfd2b98d134c744fac552c#googlebase
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 08:20:15 AM
Order the color you want for that part. Trick is from what I have read i to paint and decal before you put gas in it. You need to use the porus decals.

I have a black tank,,,,,,,,,,,,,,,,,

Thanks for the linky
I've been ordering stuff from Pro Cycle...trying to establish that repor with them and invite them in here...
Here's my concept of the operation:
Order a white or translucent tank. Then on the side add 1 gallon, mark it, then 2, then 3 and so forth until the whole thing is graduated
Then tape off that vertical 1" wide band and paint all the rest of the tank
Paint procedure: #1 Plastic adhesion promoter
#2 primer
#3 Epoxy sealer
#4 color coat which will be black or the OD Green that is in the truck
#5 then apply the cammo decal wrap
#6 Make vertical relief cutw with a razor every 1/4" inch or so to vent escaping fumes

Then I am still on the hunt for a material that I can coat the inside of the tank with, that will work with plastic.

The Armee uses this latex material to recoat the insides of the water-buffalo water trailers every few years or so which stands up...I just wonder what sort of thing works in gas tanks...plastic gas tanks.
Find that and you earn the keys to the emerald city!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 06:40:17 PM
Today, the thing was cleaned up and prepped for the mods to come

First I soaked everything with the purple stuff.

Remember the seat gets replaced and the painted surfaces all get camouflaged so what I really hoped to accomplish is a clean working surface ready to take the vinyl decal
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:10:09 PM
Then after pressure washing and hand washing, a new bike appeared!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:11:50 PM
The jury is still out, but I purchased these 1.75 gallon Roto-Pack gas tanks for the project.

Either these or a bigger gas tank
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:13:54 PM
That Corbin box actually contains a Sergeant seat

Somehow I don't think I'm going to ever live down the fact that I have anything Sergeant on the bike!

But there's a lot more in there
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:15:24 PM
And there it is, the new seat
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:16:49 PM
It's wider, and supposed to be a lot better than the stock seat
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:19:22 PM
And has some gee-whiz sort of foam

Long ago in a galaxy far, far away, when I used to strap on Special Operations Chinooks, I remember the special foam in those seats. You could actually sit there for many hours comfortably. I can only hope this seat is something like that
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:21:14 PM
And here is the rear rack that will soon bolt into place in lieu of the grab rails
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:23:18 PM
This is a brand new Cogent rear shock built in N. Carolina. THis unit was specifically developed for this bike.

I uprated the spring for a 250-270 lb. load to cover me and the gear
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:24:57 PM
The front fender brace stiffens up the front plastic and provides a Velcro base for the small inner tube bag I plan to place up there
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:26:11 PM
Here's the new Baja-Works front windshield
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:30:14 PM
This gem will give me a lot more light while reducing the draw from the stator to only 20W

I calculate I can run a heated vest, heated grips, and charge my computer while running the bike by stepping up to a 200W stator and cutting down the incandescent bulbs to LEDs
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:31:30 PM
These little mounts will help me attach two 6 bulb LED lights to the front to really create some good light
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:34:40 PM
Here's the ricochet belly pan I picked out for this bike
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:36:09 PM
Of course it gets the acid etching primer treatment
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:37:53 PM
Then the color coat

Same color as the truck

WWII OD Green
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:38:50 PM
The front fender brace got the same treatment
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:40:40 PM
The decals were all removed except for the tank, while I decide if I want to stay with a smallish 3.3 gallon tank, and carry the gas cans, or get the 6.6 gallon Aceribs tank
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 07:41:40 PM
So, at the end of build day 2, this is likely the last time the bike will be this stock...
Title: Re: DR-650 Build Thread
Post by: BobbyB on September 17, 2014, 08:50:32 PM
Why not run a larger tank and have the fuel cans anyway. No such thing as TOO much fuel, and if all else fails you can leave them attached to D2 if you won't need them.

Besides you never know if you are going to lean too much into a turn and dump it and puncture the regular tank (it's happened before).
Title: Re: DR-650 Build Thread
Post by: KensAuto on September 17, 2014, 09:16:22 PM
I agree, go with the big tank to start with.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 10:34:42 PM
Why not run a larger tank and have the fuel cans anyway. No such thing as TOO much fuel, and if all else fails you can leave them attached to D2 if you won't need them.

Besides you never know if you are going to lean too much into a turn and dump it and puncture the regular tank (it's happened before).
Well, it's a bit more complicated than all that
First the big tank can not be painted or covered with the vinyl decal because after about a week, and forever onward, it leaks fumes which cause decals and paint to fail
OK, fine, just run a black tank, and that is a possibility.
If I run the stocker, the vinyl will adhere, and I'll have two 1.75 gallon tanks on the rear, and sitting up pretty high. So 3.5 gallons, or 3.5 X 6.8 = 23.8 lbs + 5 pounds for the cans and the latch or 28.8
Now that is sitting maybe 6" above the seat. On top of that pile on a duffle bag, a bike bag which is smaller, but with kit you might need or want, say 35 pounds more. So now we have 59 pounds sitting with a Cg for the mass about 8" above the seat
Lesson in physics: What are the wheels and tires on a moving motorcycle? If you answered gyroscopes, you are correct. Depending on the weight and speed of the spinning mass, they exert "X" force.
If one applies a force to the spinning rim it will move the gyro, although the gyro will resist. Whatever force it required to move(Tilt) the wheel, it takes mush less force to move that gyro the farther away you get from the center of mass
So that 60 pound mass tucked in about at the small of your back can very much influence the roll characteristics of a bike, making it more difficult to manage, essentially running handling
Still with me?
Good, because now we have to consider the fwd/aft Cg and the effect of loading cargo outside the limits. To over simplify, you could say the fore and aft limits would be the tow tire contact patches. Now I ask you is this load on the rack inside those limits? Not really, so we must pay attention to what we stack back there and keep it reasonable or poor handling will result.
The single big tank is in about the right place fore and aft, but gets a little high, or above the bikes Cg. and with 6.6 gallons X 6.8 ppg = about 45 pounds. But I agree that it is better weight for sure.
So, I'm trying to sort through all this and figure it out. I have many options, but overall, I am going to be very mindful of total weight this machine is destined to carry
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 17, 2014, 10:35:08 PM
I agree, go with the big tank to start with.
Ya know...I probably will
Title: Re: DR-650 Build Thread
Post by: BobbyB on September 17, 2014, 11:13:52 PM
Well, it's a bit more complicated than all that
First the big tank can not be painted or covered with the vinyl decal because after about a week, and forever onward, it leaks fumes which cause decals and paint to fail
OK, fine, just run a black tank, and that is a possibility.
If I run the stocker, the vinyl will adhere, and I'll have two 1.75 gallon tanks on the rear, and sitting up pretty high. So 3.5 gallons, or 3.5 X 6.8 = 23.8 lbs + 5 pounds for the cans and the latch or 28.8
Now that is sitting maybe 6" above the seat. On top of that pile on a duffle bag, a bike bag which is smaller, but with kit you might need or want, say 35 pounds more. So now we have 59 pounds sitting with a Cg for the mass about 8" above the seat
Lesson in physics: What are the wheels and tires on a moving motorcycle? If you answered gyroscopes, you are correct. Depending on the weight and speed of the spinning mass, they exert "X" force.
If one applies a force to the spinning rim it will move the gyro, although the gyro will resist. Whatever force it required to move(Tilt) the wheel, it takes mush less force to move that gyro the farther away you get from the center of mass
So that 60 pound mass tucked in about at the small of your back can very much influence the roll characteristics of a bike, making it more difficult to manage, essentially running handling
Still with me?
Good, because now we have to consider the fwd/aft Cg and the effect of loading cargo outside the limits. To over simplify, you could say the fore and aft limits would be the tow tire contact patches. Now I ask you is this load on the rack inside those limits? Not really, so we must pay attention to what we stack back there and keep it reasonable or poor handling will result.
The single big tank is in about the right place fore and aft, but gets a little high, or above the bikes Cg. and with 6.6 gallons X 6.8 ppg = about 45 pounds. But I agree that it is better weight for sure.
So, I'm trying to sort through all this and figure it out. I have many options, but overall, I am going to be very mindful of total weight this machine is destined to carry

Flat black paint job, no vinyl needed on the tank. You made it too complex for a grunt.... Simplify it.

Heavy rucksack not loaded correctly, off balance grunt in unstable footing... falls over...

Properly packed and balanced ruck..grunt NOT fall over..

Pilots always using them fancy learnin words...
Title: Re: DR-650 Build Thread
Post by: JR on September 18, 2014, 12:19:48 AM
With what they do to gas today, or tomorrow who knows what will hold up.

If you are going to do a cammo wrap just do that. Just get it perforated and it should be fine.

(darn I wrote this at 1400, how did it get down here!)
Title: Re: DR-650 Build Thread
Post by: JR on September 18, 2014, 12:33:27 AM
Just go with the 5.3 tank and ad items to the rear rack and some saddle-bags. There are also great tank packs that you can hang all kinds of stuff on. Around the waist is not that bad but remember you will be up and down in that seat, comfy or not. Your legs are half the suspension and affect those gyroscopes alot!!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 10:13:00 AM
Just go with the 5.3 tank and ad items to the rear rack and some saddle-bags. There are also great tank packs that you can hang all kinds of stuff on. Around the waist is not that bad but remember you will be up and down in that seat, comfy or not. Your legs are half the suspension and affect those gyroscopes alot!!
Ya know...
Was thinking about the 5.3, with one roto-pack 1.75 on the back
Sort of a compromise
Keeps weight almost 2" lower...Don't have to put fuel in the roto tank out back...
and is equal to a tad over 7 gallons
With the 790 big bore kit I will be able to use much lower RPM's to motor along which equates to fuel savings. Then with a properly tuned carb, I might be able to stay in that 43-50mpg range. That would give me the two days roamin' un-refueled range that me thinks would be smart with this recon bike setup
Or if I had to get on the run a minimum range of around 300 miles
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 10:15:27 AM
Well, it's a bit more complicated than all that
First the big tank can not be painted or covered with the vinyl decal because after about a week, and forever onward, it leaks fumes which cause decals and paint to fail
OK, fine, just run a black tank, and that is a possibility.
If I run the stocker, the vinyl will adhere, and I'll have two 1.75 gallon tanks on the rear, and sitting up pretty high. So 3.5 gallons, or 3.5 X 6.8 = 23.8 lbs + 5 pounds for the cans and the latch or 28.8
Now that is sitting maybe 6" above the seat. On top of that pile on a duffle bag, a bike bag which is smaller, but with kit you might need or want, say 35 pounds more. So now we have 59 pounds sitting with a Cg for the mass about 8" above the seat
Lesson in physics: What are the wheels and tires on a moving motorcycle? If you answered gyroscopes, you are correct. Depending on the weight and speed of the spinning mass, they exert "X" force.
If one applies a force to the spinning rim it will move the gyro, although the gyro will resist. Whatever force it required to move(Tilt) the wheel, it takes mush less force to move that gyro the farther away you get from the center of mass
So that 60 pound mass tucked in about at the small of your back can very much influence the roll characteristics of a bike, making it more difficult to manage, essentially running handling
Still with me?
Good, because now we have to consider the fwd/aft Cg and the effect of loading cargo outside the limits. To over simplify, you could say the fore and aft limits would be the tow tire contact patches. Now I ask you is this load on the rack inside those limits? Not really, so we must pay attention to what we stack back there and keep it reasonable or poor handling will result.
The single big tank is in about the right place fore and aft, but gets a little high, or above the bikes Cg. and with 6.6 gallons X 6.8 ppg = about 45 pounds. But I agree that it is better weight for sure.
So, I'm trying to sort through all this and figure it out. I have many options, but overall, I am going to be very mindful of total weight this machine is destined to carry

Flat black paint job, no vinyl needed on the tank. You made it too complex for a grunt.... Simplify it.

Heavy rucksack not loaded correctly, off balance grunt in unstable footing... falls over...

Properly packed and balanced ruck..grunt NOT fall over..

Pilots always using them fancy learnin words...

OK, so what did I get from this?

New term

No longer K.I.S.S.

Nope

From now on

K.I.G.S.

So when you hear me say Kigs, you know what I'm talkin' bout'
Title: Re: DR-650 Build Thread
Post by: BobbyB on September 18, 2014, 10:41:38 AM
OK, so what did I get from this?

New term

No longer K.I.S.S.

Nope

From now on

K.I.G.S.

So when you hear me say Kigs, you know what I'm talkin' bout'

And they say you can't teach old dogs new tricks!  :)
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 10:46:54 AM
I'm slow

But at least, I do poor work!

and I am learnable!
Title: Re: DR-650 Build Thread
Post by: moto123 on September 18, 2014, 02:13:27 PM
+1 for the larger plastic gas tank.  Acerbis as you noted make a good one (and it is pronounced a-chur-bees) Clarke is also a good gas tank manufacturer, I didn't look to see if they make one for the DR650 thou.  As far as graphics, yes graphics or decals will stick to the tank.  But you definitely want them vented with either a pattern of small holes or slits.  It will take many years, but eventually the graphics could turn slightly yellow or begin to peel.  But that is so many years down the road, I would not worry about it too much.

Not sure if it has been considered or not, but a bike only tool box could be created and stored on SquareD.  This would contain any specialty tools for the bike, but more importantly a spare part for all of the critical components and things that are easy to break.  The oil cooler and oil lines come to mind first, and a spare carb could be handy also.  Also spare tubes, unless you plan to go the tubeless route and install a bib mousse in each tire.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 03:12:38 PM
Wow, got traffic already, and I didn't even know the site was completely open to the public
What the heck. WELCOME!

Ordered the alphabet 6.6 gallon tank in natural plastic color this morning along with some protection pieces and a full exhaust

Spare parts: Check. Some carried on the bike, some on SquareD

Adding the BOTK (Big ole tool kit) to replace the stocker, then go with a good selection of tools as I saw recommended by some crazy Brit who drives around the world as a part time hobby.
Spare tubes and patches and tire irons: Carried on front fender and in rear tool kit, check!

Good suggestions! Keep em comin!
Title: Re: DR-650 Build Thread
Post by: Rescue Man on September 18, 2014, 04:28:50 PM
Don, I see you did decide to pint that Ricochet skid plate. I have to say I dig the green on it. I think in the long run it will be easier to repaint then it would be to re bedline after a good knock. I look forward to seeing this bike come together!

Rescue
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 05:55:24 PM
Well, as this knee of mine comes back together, the bike and SquareD will also

So to that end let's install some stuff

First the richochet plate...well I changed colors...
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 05:56:07 PM
Here's where action central is for the next 30 minutes
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 05:57:19 PM
The hardware is simple. The welded in place nuts are the locking type so I gave everything a light coat of red grease first
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 05:58:51 PM
The plate slips right up in there with little or no fuss.
Just get a couple of the J-Clamps started and you're off to the races
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 06:00:57 PM
Then the other two bolts and some tightening and I have a partially protected crankcase!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 06:02:38 PM
OK, that project is in the bag...Next...
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 06:05:45 PM
Next, since the previous owner who is a bit shorter than the bike was designed for, the triple clamps were slid down about an inch
For a big guy like me, they're going back up

Loosen a few bolts and those suckers moved right back where they ought to be
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 06:07:33 PM
Man, I wish that lifting trucks was that easy!

While the triple clamp bolts were loose, I installed the aux LED light mounts
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 06:11:06 PM
Then I discovered the turn signals will occupy the same space as the new LED's
OK, quick check with sir Issac Newton and I came up with this: Two chunks (well maybe not chunks) of matter cannot occupy the same place at the same time.

OK turn signals have to move...How bout here?
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 06:12:25 PM
Well, seems Newton's laws were still in play...turn signal limited the front wheel from turning

OK, bad idea

Know what success is

It is one good idea on a pile of bad ones!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 07:56:44 PM
So I found a better place for them...Here:
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 08:00:36 PM
Next up, while access existed is the simple install of the 3600 Lumen LED headlight bulb
We're talking going from 60-90 watts down to 20 something
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 08:03:42 PM
So the battery in the camera failed, so not as many shots from here onward. But here is how I solved the turn signal problem. Using a big fender washer to spread the load, I mounted up the lightweight turn signals to the fairing
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 18, 2014, 08:05:19 PM
Then the fairing went back on and that completed the job, task, and day...an end to build   day 3
Title: Re: DR-650 Build Thread
Post by: JR on September 19, 2014, 03:01:57 AM
Surprised this hasn't found its way to you yet;

http://shoraipower.com/
Title: Re: DR-650 Build Thread
Post by: BobbyB on September 19, 2014, 09:26:46 AM
So when's the "oil change" happening...
Title: Re: DR-650 Build Thread
Post by: Mrwoody on September 19, 2014, 12:41:49 PM
The hardware is simple. The welded in place nuts are the locking type so I gave everything a light coat of red grease first
Title: Re: DR-650 Build Thread
Post by: moto123 on September 19, 2014, 01:10:44 PM
Don't get too carried away mounting the LED lights until you have installed some aluminum hand guards.  They can't occupy the same space.  Plus the hand guards might actually give you a better location to mount the lights.

Other thoughts, upgrade to 1-1/8" handlebars (renthal fatbar or protaper).  These bars are much stronger than the one you have currently on the bike, plus they will allow a larger flat space on top of the bar to mount GPS and other items.  But you will want to do this before the hand guards so you get the right size hand guard mounts.

Yet more thoughts, I believe the DR wiring forces the headlight and tail light to be on when the engine is running.  You will probably want to wire in some sort of override circuit that can allow the bike to run without lights - thinking night stealth.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 19, 2014, 01:21:54 PM
You're on!

Good thoughts

I see you too have the TBC (Tactical Brain Circuit) and are similiarly afflicted as I am...I know a good doctor, BTW...

Bummer...Ordered the hand guards yesterday from ProCycle. Ordered the new aceribs or whatever that greek name is...
So you just told me I screwed up

BTW, the handlebars on the bike are upgraded...Dunno if they are 7/8", 1" or 1 1/8".

Copy on the lights thing...
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 19, 2014, 01:46:15 PM
Surprised this hasn't found its way to you yet;

http://shoraipower.com/
Looked at them JR
I'm concerned about circuitry in a lithium battery (Doesn't it have some??) vs dirt floor simplicity of lead acid
I noted that they did not have a battery for the 2012 DR, only the 90-19 model...misprint possibly
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 19, 2014, 01:53:33 PM
So when's the "oil change" happening...

Happening now!
List of mods:
Forks:  Done
Headlight:   Done
Rear shock:   Parts on property
Gas tank:   Ordered
Rear rack:   Parts on property
Case protection:  Parts enroute
Handlebar:  Installed
GPS:  Partially installed
Aux lights:  Parts on property
Camo:  On order
Exhaust:  Parts on order
Seat:  Parts on property
Windshield:  Parts on property
200Watt stator: no action yet
Skidplate:  Installed
Tires: Awaiting decision
Aft fuel tank:  Parts on property
Bags: Selected, not ordered yet
40mm Mikuni carb:  Selected awaiting ordering
790 cc Big bore kit: Parts selected, awaiting ordering
High-performance head and cams: Parts selected awaiting ordering
Oil Change: Not even considered:  Yikes!
Title: Re: DR-650 Build Thread
Post by: Drunksailor on September 20, 2014, 06:08:07 PM
Just a thought, being a guy that spends more time on two wheels than four, instead of having your bike bag strapped to the bike have you considered strapping it to you. Not only does this drastically improve your COG issue (doing any trail riding you will be moving the bike under you and you can control the weight better if you are the weight), also if you have to opt out from your bike or get thrown from it during evasion you might not have time to grab it. This is a situation i believe you Don call being up a creek and your paddle is still on the bike, not to mention this might add slight protection for your buttocks if someone threw little chunks of lead at you as you drive away.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 20, 2014, 06:36:20 PM
Well, I was thinking of wearing my lightweight kit on the bike, same-same as we used in haji land...
Title: Re: DR-650 Build Thread
Post by: JR on September 20, 2014, 07:58:55 PM
I had the light kill switch on my 350 with an indicator it was off.

Wearing what you need vs what the bikes needs is a good balance. Strap basics on the side racks, forks and tank. Your needs around your waist leaving the top of the rear rack clear for whatever pops up or a quick grab bag for you.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 20, 2014, 09:34:30 PM
Hmmm,

Plan was to add one roto-pack 1.75 gal tank
On top of that a Wolfman large H20 proof duffle
Two sizeable, but maybe not full saddle bags, a small case for a laptop somewhere, bag of spare stuff on the fender, took kit under the left rear cover, and a tank bag for quick stuff

Now hear this:
Every piece that I am going to wear or carry is going to go through the weight test thing
All light weight high tech clothing. light weight tent, stove, bag, ground mat, light, this/that...everything
Title: Re: DR-650 Build Thread
Post by: moto123 on September 22, 2014, 01:19:23 PM
Bummer...Ordered the hand guards yesterday from ProCycle. Ordered the new aceribs or whatever that greek name is...
So you just told me I screwed up

BTW, the handlebars on the bike are upgraded...Dunno if they are 7/8", 1" or 1 1/8".

The TAG bars that are on the bike as of the last picture are definitely an upgrade over the stock ones.  But since they have a crossbar, I believe they are still 7/8" diameter.  If you already ordered the hand guards to match the 7/8" bar then I would just use it like that.  Upgrading further to the 1-1/8" bars may be over kill for this application.  The larger bars would also require an adaptor kit.  One advantage to the 7/8" bar is that since it was historically a common size, finding a spare set on the side of the road when needed in an emergency could be far more likely than finding a 1-1/8" set.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 22, 2014, 06:52:39 PM
I am told these tag bars taper to 7/8" which I think is stock.

I'm just going to work with most of the things I have to keep it all fairly simple and save a few dollars.

I am still awaiting the camo sheet to arrive

There seems to be aproblem with the CamoSkinz folks with knowing where my stuff is. All we know is that I paid for it. The big teardown will happen when that stuff shows so that I can apply it to all the body parts.

And I have an order inbound from Pro Cycle of more parts. With that order I will be past the 50% point with respect to mods
Title: Re: DR-650 Build Thread
Post by: JR on September 22, 2014, 08:08:07 PM
Uh, have you changed the oil yet????????????? (OK we need smiley links!!!)
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 22, 2014, 08:35:10 PM
Uh, have you changed the oil yet????????????? (OK we need smiley links!!!)

Nope, waiting for Mr.Manners (Willie) the Amsoil man to show up here!
Title: Re: DR-650 Build Thread
Post by: JR on September 22, 2014, 11:08:05 PM
Don, ref the "laptop have you though about a tablet instead? Fingertip control and gps, mapping,  plus you get the camera and long battery life. Biggest bonus is the lighter weight or lack of.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 23, 2014, 04:17:27 PM
JR,

Meant tablet
Own a Lenovo tablet touch screen or old school wood pecker keyboard
Weighs like 1 gram, really small
It's going traveling with me!
Title: Re: DR-650 Build Thread
Post by: JR on September 24, 2014, 02:05:08 AM
Throw a little solar panel on and you are topped off and ready to go.

I have an Acer, solid little thing but needs a real USB plug.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 24, 2014, 08:23:16 AM
I was going to run a USB off the bikes battery to the computer's storage case

I think Pro Cycle sells a kit
Title: Re: DR-650 Build Thread
Post by: turn_one on September 24, 2014, 02:57:19 PM
Chief!

Couple of thoughts now I've read through your 650 build:

-moto123 has some sound advice, I like his thinking.

-You raised your triple clamps to flush to the fork caps. Is this the stock location?  I'd find out but of course if those forks have different springs and valving stock location won't mean a lot.  Point is, the bike will turn radically slower now with that much decreased rake. Lower front end = faster turn in but to a point can be unstable.  Higher front end = slower turning but more stable.

-I know a lot of your stuff is built to be burly, most people on this site will champion this approach.  As we've discussed there's a benefit to being light and fast...since you've already screwed yourself by buying a DR650 I guess my point is moot.

-Check out this as a cool option to carry stuff.  https://www.rockymountainatvmc.com/p/1409/16178/Ogio-MX-Flight-Vest  A lot of guys I ride with talk highly of it; there's a spot for everything...and I'm guessing you may know a thing or two about a 'flight vest.

You guys need some non-Suzuki shots in here from the PNW:

(http://i30.photobucket.com/albums/c344/turn_one/IMG_1040_zps74a632f4.jpg) (http://s30.photobucket.com/user/turn_one/media/IMG_1040_zps74a632f4.jpg.html)

Well sorta, the puke yellow bike in the back is a DR650:

(http://i30.photobucket.com/albums/c344/turn_one/IMG_1068_zps99dea44b.jpg) (http://s30.photobucket.com/user/turn_one/media/IMG_1068_zps99dea44b.jpg.html)
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 24, 2014, 03:09:11 PM
Just so everybody knows:

1. This guy is my son...the tallest one

2. He secretly confided in me that the Dr650 might arguably be the best 'round the world bike...just sayin...

3. I don't know any triple clamp, turn in nonsense...

Now, let's see a thread on that 690 and that trip up to B.C.
Title: Re: DR-650 Build Thread
Post by: turn_one on September 24, 2014, 03:36:50 PM
In response to pops:

1.  The ugliest one

2.  True, will last forever, made form steel and strong stuff.  But not the most fun on a RTW trip.

3.  Ride a few figure 8's in the driveway as the bike sits, then lower the bikes triples 15mm and do the same...should be a noticeable       difference...modify this difference with speed.

TR upcoming.

Looking forward to this DR build...


Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 24, 2014, 08:45:18 PM
You think you're the ugliest?

OK, 15mm...

I can't ride now...all gimped up still...
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 08:45:18 AM
BTW, his name is "Little Don"

Why?

Well, I am "Big Don" so it was natural to call him LD

Funny, when we were first in the regular Army at Ft. Campbell, I was the SIP which is like the chief pilot, and everyone called me Big Don and everyone knew Little Don.

There was another pilot in the unit called Don

The guys named him "Medium Don" and the name stuck

So in getting to know this illusive sorta outward bound son of mine, here's a story I wrote about his childhood for a book I was writing, but never completed:

Chapter 1

Dad The Trash Blew Up!

By

Donald Harward


Raising a family was and continues to be a source of fun and amusement for me. Kids do the craziest things and we as parents are wholly unprepared for the daunting task at hand. Having a family while knee deep in a career is all the more challenging. There always seems to be a fine line one has to walk between career and family needs with the balance in constant ebb and flow. With my family that career was one in the military, specifically, the US Army.

Throughout this story and the many which will follow the focus will center around the exploits of a young boy with my namesake, Don. I will attempt to detail his many experiences while growing up in the surreal world of the military while living in a family that moved around the world and was very near ground zero for a number of historical occurrences.

This story will not take place in the beginning of his wildly fantastic adventure but about one third of the way to him becoming a young man and finally leaving. He would have been somewhere around thirteen years old and in the sixth grade. I am a bit foggy about the exact timeframe, but not at all on the incident that gives its name to this story. No that is a very vivid memory indeed. This story takes place in our home, our very first house tucked away in Rural Tennessee on Lannom Road in Clarksville. If you have ever heard the Elvis song, last train from Clarksville, that’s the same place!

We hadn’t been there at our “new” house all that long, I had purchased it a few months earlier and was enjoying having Don live there and adjust to his new life. We had recently lived in Main Sondheim, Germany where we occupied a smallish apartment for the previous several years. We felt a loss from having left that friendly village where we were one of only two American families in a town of about a thousand. While there, over the months and years we had worn ourselves into the very fabric of that town and into the hearts of many of its residents. We had grown to love them as much as they loved us and in those early days in Clarksville the thoughts of lost friends and of that place was never all that far away.

When I first came back from Europe I had been assigned to a classified (secret) unit in the Army located at nearby Fort Campbell. Because of the difficult and demanding training requirements I had to endure, there was literally no time for anything else other than training and some badly needed sleep. Because of all of that Little Don could not accompany me when I first reported to Ft. Campbell and for many months thereafter. Instead he stayed with my father and mother in Maryland.
 
He was many hundreds of miles away and my off time was nearly nonexistent, so we saw each other very little for the first few months after we all left Germany. I sort of liked the idea, however, that he would get to live with his grandparents for a time and get to know them much better. From all reports, things were going well for all concerned but we wanted to be back together once again.

I didn’t really have a plan for where to live when I first reported to that new unit. I had never owned a house before, only lived in various apartments during those early years. To own a home seemed like an unobtainable dream to me, still a young officer with limited financial means. But as time went by I thought more and more about living in the country, in a real house that we could call our own.

I had grown up in a rural setting in a very old town, Abingdon, in Harford County, Maryland near the shores of the Chesapeake Bay. My memories of that place were thick enough to slice with a knife. There was the church I occasioned, Cokesbury, which was the site of the first Methodist College in the colonies. On nearby Ha-Ha Branch, a small community a couple miles away, some of our family still lived on land which had been granted to them by Lord Baltimore, the first British Ruler of that area of what would become the United States. I had lived a youth of outdoor adventure replete with almost daily hunting, fishing, sailing, or similar activities. My brother and later my sister had known real freedom and we did not know of the widespread crime and concerns of our modern America. No, back then a child was free to roam the country as he saw fit, and the next adventure was waiting for the adventuresome just on the other side of the large Oak tree or around the bend.

Having enough maturity at the time to realize the importance of all of that as it pertains to the development of a young man’s character, I wanted that for Don also. That was the spark and motivation for the decision to seek a proper house in the country where he would learn and grow. That house, as it turned out was very easy to find. I must say and give due credit here to a certain divine spirit that in retrospect has been at the root of a great many of my decisions which I have made along the way. When we are young we have a strong belief in self. We are strong, fast, fleet of foot, and seemingly on top of our game. It is complete folly though for one moment to think that we actually did any of that in our own power. Actually (and in my opinion) that it is only with a great effort from somewhere else that actually contrives to connect all the dots and get us through to a good decision and outcome.

That good decision for me began with selecting a realtor of local distinction and by paying him a visit on one of my rare Saturday’s which I had off. I even remember the office. It was a brownish affair with cedar plywood panels adorning the sides and a rather average awning and single glass door. More like a home actually than an office in appearance, it had the immediate feel of being “right.”

Inside sat a husband and wife team who listened patiently while I went on about our particular needs and circumstances. They asked the pertinent questions, politely interrupting me only on a couple occasions while they scribbled a couple notes and nodded. I thought I’d try to make an impression, and while describing exactly what I wanted, also make me look like something other than the complete novice which I was at that time.

“We are looking for a three bedroom on some land out in the country with a wood burning heater and we want it to be brown!” The last little bit of my statement elicited both a raising of the eyebrows and a smile. The gentleman realtor answered immediately, “I know the exact house you want, but I’d suggest we look at two others first then visit the one which I believe will fit your needs perfectly.

He owned a large Cadillac Coupe Deville. Powered by a 500 cubic inch V-eight and looking like the Queen Mary with its somewhat faded aqua blue paint, we all got in and drove away. The first stop was to a home in a nearby community which had the proper size and number of bedrooms. That house was in fact brand new and had a price tag of some sixty thousand dollars. Back in nineteen eighty four that was big money. Especially for a junior pilot struggling with various payments including a new car. Further the home had many other homes built all around it. I couldn’t picture little Don leaving the house on a hunt for squirrels with his trusty twenty-two rifle, so we moved on.

The next home was a similar design. This second house was a ranch of about fifteen hundred square feet with three smallish bedrooms and a couple bath rooms. It too, would meet our basic needs, but was a little bit too much money and didn’t have open ground on which to roam.

Those two homes were located in the suburbs of Clarksville which exhibited the typical urban sprawl of a growing bedroom community. Mighty Fort Campbell was the economic engine of that place where it housed the mighty 101st Airborne division and my secretive unit. Over twenty thousand hardened combat troopers worked and trained there and supported a town of fifty thousand just outside the gates of that one hundred forty five thousand acre base. All of that is situated on the northern side of the Cumberland River which flows up from Nashville to the south and empties into the huge Kentucky Lake area to the north west. On one side of that river was suburbia and a wonderful old town, on the other side was near wilderness.

Driving along riverside drive on the south side of Clarksville we turned southwest in that giant Cadillac. Not far away and looming ever larger was an ancient narrow Iron bridge that looked like it had already lived its better days. We made a right turn and started up a long, climbing ramp that led directly toward that bridge. Pulling onto it I wondered if it was even two lanes wide? Was it groaning and creaking as we made our way across? It led to a rampart of hills overlooking Clarksville to the north east. The area we were entering was known as Cumberland Heights, but locals referred to it as string town. I never was quite sure why the name, but I can attest that it was like a different country by comparison to nearby Clarksville. Only hardened locals lived “out here.”

The road wandered from turn to turn as it meandered along the crest of the ridge ever farther away from Clarksville and from civilization. I wasn’t paying that much attention but in about two to three miles we slowed and made a hard left turn onto an oil coated  dirt road. A crooked green and white street sign sticking out of the ground in a honey suckle patch said “Lannom Road.” We would learn later that the road had been named for our very neighbor, Mr. Lannom who had actually pushed enough dirt around to create the road in the first place when he built his house many years earlier, literally out in the woods.

At the very end of Lannom Road a gravel driveway on the left curved around gracefully back to the right, first downhill then back up and ended right in front of a single level brown ranch house. It was deep in the woods positioned on the top of a spur overlooking what locals called a “holler,” which was a valley. At the bottom of that “holler” flowed a perennial stream which worked a crooked path down to the Cumberland river not too far away.

Planting a foot on that gravel, I knew this was the place. Don could make a good run from here. The woods would teach him, the locals would harden him and teach him country ways, and together we would grow and experience many things here. The tour of the house’s interior was almost inconsequential as I just had that feeling that this was going to be our home. The master bedroom was small, as was everything else including the asking price. That was a very affordable $45,000 and it even had a wood burning stove augmenting the heat pump which droned in the back side of the house. For the added sum of only one thousand dollars, I could purchase the adjacent six acres of land making out total property a little over seven acres.

Mr. Realtor was very adept at reading his customers and he had done his job well with me. He saw the look on my face and I think he could see my mind’s eye visualizing my watching Little Don run through the woods on a day of discovery. “Do you want to make an offer” he asked? “I believe the seller is very motivated.” While looking over the expanse of the “holler,” I replied, “Yes, this is the place, this is our new home.”

The process went very well and also quickly, as does nearly all things that are of divine origin. In no time we had an agreement with the seller and a contract, and a willing bank to loan me the money. I called little Don the next week to tell him the good news. He would soon be coming to Tennessee to live in his new home and lay claim for the first time to his very own bedroom. Maybe it meant more to me than him, you’ll have to ask him that question, but I recall it a sure felt right at that time.

Before long, Don had come and life was settling into a familiar pattern. He had quickly found new friends, been integrated into his new elementary school, and even gotten a dog. I was very pleased with how he seemed to be assimilated into the local southern culture and before long, we had the feeling as though we had lived there for a long time. I was surprised at just how fast Don was developing. Before when living in that tiny third floor German apartment, he was somewhat limited by what he could do, but not here. In these rolling hills and thick woods was a life unfolding and exploding in all directions. I was still very busy with the Army and was often gone on some training mission or supporting this organization or that. The world was a very dangerous place at the time, as it remains to this day, I suppose, and my new outfit was a sort of nine-one-one force policing all of it. The calls would come unexpectedly at all hours and I’d be off for an undetermined period of time. But after returning I’d get another snap shot of my son’s continual development.

While constantly expanding the horizons on what he could do, and what I would allow him to do, he attained more and more responsibility. I was allowing him to venture out to who knows where for hours on end. He was shooting, playing sports, chasing the dog all over creation and just having a run of it. While allowing the growth outside of the home to continue, I was also encouraging more and more responsibility in the home. Don was very receptive to the idea, always eager to please and continually seeking more and more responsibility.

I had a lively hobby of working on cars at that time. It seems we always had some car project going and on some of them, Don was very much involved. The garage we had at the time was actually in the basement below the first floor. There, one tiny bay was the site of engine builds, body repair and repainting and hot-rodding of all sorts. Following any project, the mess created was usually considerable. Afterward or periodically during a project I would clean up the mess and bag the cans and other plastic and metal items for disposal in a nearby dump. You see, we did not have the luxury of a trash removal service so the accepted technique was to burn the paper products, compost the food and organic items and haul the metal and plastics to the dump. To those ends we all had compost piles and burn barrels.

We owned a fifty-five gallon barrel and thirty gallon trash can for that purpose. About two to three times a week, I would gather up the bags of paper and Don and I would haul them a short distance down the hill to a leveled off spot we used to burn the trash. Don seemed fascinated by the power and the mystery of the fire thing and as time went along, I would let him do more and more to help. Eventually, I let him start the fire and monitor it as was required to prevent accidental spreading to the nearby grasses and trees.

On the fateful day, I seem to remember it was an autumn day. I was relaxing on the couch watching TV following a long “day at the office.” My eyes were heavy and I was looking forward to supper and an early night. I had left the house around five AM to go to PT (physical training) on post and had flown some during the day. The cold weather had taken a toll and all in all, I was toast. Little Don presented himself and asked if he could burn the trash. The question was presented in such a manner as to suggest, that he wanted to burn it himself without my presence. I thought about it for a moment. This was one of those decisive moments and a chance for me to show him that I trusted him with something potentially dangerous. There didn’t seem to be all that much risk, a recent rain had dampened the leaves and grass so the risk of a fire spreading was low. “Sure Don, go ahead, have fun.” I could see the slight change in posture as he crossed into a new realm of trust between him and his dad.

It’s funny, but you are just never prepared for all the folly that is always waiting patiently just out of sight to erupt onto your placid landscape and smack you right in the forehead. I believe I was somewhere between sleepy land and the conscious world when I heard the first in a series of explosions.

I came wide awake instantly, but my mind was not there in my house. Nothing fit just right at that moment. I thought I just heard a volley of 2.75 inch rockets slam into the earth producing that muffled “Whump, whump” sound. Then in an instant I knew it wasn’t that at all. I jerked my head around toward the window just in time to see a ball of black smoke spreading outward from where the burn barrels were. I got an instant sick feeling of doom as I flew out the door and turned downhill toward where Don should be. I didn’t know what I was about to encounter, or how this had happened, but I was scared, real scared. In a flash I saw him staggering uphill walking toward the house. He was covered with black soot from head to toe! He looked just like Wiley Coyote who had just been blown up while holding a handful of dynamite. His black stained cheeks had two trails of pink skin where the tears were washing away the soot. His hair was full of tatters of paper and everything else imaginable, but I could see no visible damage. He was shaking and crying as I walked the last couple feet to him but no blood. Through those green tear filled eyes he looked up at me and uttered those words I will never forget, “Dad, the trash blew up!” I didn’t know whether to laugh or cry!

After some inspection I could see he was not harmed at all, just startled and scared. Behind him beside a trash barrel which had been partially blown apart were the remnants of some shattered spray paint cans. I immediately knew what had happened. While grabbing the bags of trash he had collected one or two which contained paint cans from where I had cleaned the garage earlier. Those bags were intended for the trash dump and obviously, not for the burn barrel. In his zeal, born from his newly found trust, he had collected all the trash in the spirit of doing a good job and impressing his father. But as with all things the result is not always what we might expect. The outcome from this little “learning experience” was not a bad one, but certainly was a memorable one. As it would go with many of the things which would happen to Don over the years, he would survive intact and in good spirit. He would as we say in the Army, “live to fight another day.”
Title: Re: DR-650 Build Thread
Post by: moto123 on September 25, 2014, 01:13:23 PM
You sir, are certainly not at a loss for words.  Still, a pretty amusing story!  My own son is 3-1/2 years old currently, so I expect to have many similar stories to tell in these up coming years.
Title: Re: DR-650 Build Thread
Post by: moto123 on September 25, 2014, 01:24:53 PM
turn_one, I agree.  We needed some pics of the "fun" style of adventure bike.  Here is my 2007 KTM 525EXC in my front yard early this spring.  This was the first year these came as street legal.  Which opens up another whole can of worms on the discussion of why are there tons of awesome bikes available in Europe that we are not allowed to purchase in the US..... crazy!

(http://i596.photobucket.com/albums/tt49/moto123233/20140325_180502.jpg) (http://s596.photobucket.com/user/moto123233/media/20140325_180502.jpg.html)

And some pictures as it currently sits in my shop today.

(http://i596.photobucket.com/albums/tt49/moto123233/20140717_205715.jpg) (http://s596.photobucket.com/user/moto123233/media/20140717_205715.jpg.html)

(http://i596.photobucket.com/albums/tt49/moto123233/20140717_205737.jpg) (http://s596.photobucket.com/user/moto123233/media/20140717_205737.jpg.html)
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:44:43 PM
I like it!

Couple of years ago I was on the warpath to buy one of those. Bunch of guys my age around here go for day long adventure rides. We have so much off road available. But it never came about...
I'll make the dr a 790 all ported and cammed and maybe be able to keep you guys in sight
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:51:52 PM
Got a box of parts today
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:53:03 PM
Contained these cool Aceribs hand guards
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:54:01 PM
And an exhaust and a tank...
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:55:44 PM
So I decided to bolt on the exhaust system
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:57:47 PM
The factory system came off very easily

It weighs sooo much more than the aftermarket FMF system, like maybe 2-3 times more
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 04:59:58 PM
The head pipe with the power bulge device which I hear controls noise just a bit went right on. It's so easy working on these simple machines
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 05:01:35 PM
The fit was spot on
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 05:02:54 PM
Look at all this catalytic converter business:

Weight upon weight, upon heat...
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 05:04:24 PM
Next the muffler band clamp bolts to the stock location
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 05:07:06 PM
The stock system had two bright aluminum colored covers. I gave them the John Deere Blitz-black treatment and bolted them back on
Title: Re: DR-650 Build Thread
Post by: BobbyB on September 25, 2014, 05:33:53 PM
Since you're removing stickers, and making shiny things black,why not leave the bike gray? Gray blends in quite well from dusk to the time the big orange ball makes an appearance. Plus it'll get dirty, eventually, if someone rides it....
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 05:44:27 PM
Ya know Bobby, that just might happen

I ordered some sheet camo vinyl from Camo Skinz

It would appear the only thing they did is take my money.

I have no camo, no tracking info, nada

I have contacted the owner Jim several times and he hasn't done anything of consequence

It's too early to call this company a bad one, but he is located in VA, so I picked someone nearby

Well after a week and nothing showed, and no tracking number, I contacted him, well tried. He didn't answer, so I contacted him again. He told me he would look all into it and let me know. That was last week.
I feel it was a bit deceptive of him to sell but not tell me the stuff was shipping from CA. But with no information, it appears obvious that he is playing me. I nor this web site will support businesses that do that.
I think I just decided to fire him!
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 07:37:56 PM
I did fire him

Getting my money back, ending any relationship that was started.

So now I am cammo free, again

Had a cool pattern as well...

Decisions...decisions...decisions

Go with another vendor or just stripe it up meself like I did on the Gator

Hmmm
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 25, 2014, 07:39:38 PM
Wait till you see that big honkin' tank go on tomorrow

Dwarfs the stocker!
Title: Re: DR-650 Build Thread
Post by: BobbyB on September 26, 2014, 01:21:36 PM
My opinion, leave it gray. No real need to camo it up. You've said it before, and I've said it. Dirt helps add camo, and its more natural that way. Sure I'd have a couple can's of matte gray paint for those spills and etc, but I'd stay gray.

Remember way back when on D2, you said you wanted a stockish looking vehicle to blend in, in plain sight? Well same thing with the bike. Too much attempt to camo/low observable scheme will make it stand out more.

That's my opinion.
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:17:46 PM
My opinion, leave it gray. No real need to camo it up. You've said it before, and I've said it. Dirt helps add camo, and its more natural that way. Sure I'd have a couple can's of matte gray paint for those spills and etc, but I'd stay gray.

Remember way back when on D2, you said you wanted a stockish looking vehicle to blend in, in plain sight? Well same thing with the bike. Too much attempt to camo/low observable scheme will make it stand out more.

That's my opinion.

Good thoughts, let me think about it
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:20:28 PM
I added some hand guards as well

I started with replacing the bent brake lever
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:21:32 PM
Here is the hand guard kit which has both a thick aluminum section and a plastic cover
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:23:28 PM
The thing locks into the end of the handlebar with a largish expansion bolt
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:26:05 PM
The thing bolts to the anchor bolt then to a fixture which encases the handlebar making it all quite strong
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:26:59 PM
The aluminum bar looks like it will protect quite well
Title: Re: DR-650 Build Thread
Post by: Flyin6 on September 26, 2014, 02:28:12 PM
It all looks like it will perform its function quite well
Title: Re: DR-650 Build Thread Part 1
Post by: moto123 on September 29, 2014, 01:55:47 PM
I can guarantee from MANY personal experiences that the aluminum bark busters do a very good job of protecting your hands when you slam into trees.  Although I have tried, I have never bent a set.  Usually either the top triple clamp will shift or the handlebar will bend before the bark buster bends.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2014, 03:27:27 PM
Good News!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2014, 03:29:22 PM
Next up on the mods list are these stainless steel case protectors that Pro Cycle manufactures for the DR
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2014, 03:30:24 PM
Which I painted black, John Deere chassis blitz black to be exact
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2014, 03:32:29 PM
Installation is as simple as squeezing out a couple beads of silicone gasket sealer/maker and smashing them into place
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2014, 03:35:31 PM
And you get this: A semi-permanent upgrade to the thin casting aluminum engine side castings and covers
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:14:17 PM
So let's go bigger

more fuel that is

OK first up, off with the seat and side covers
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:15:56 PM
Then the puney 3.3 gallon stock tank
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:17:42 PM
The new tank is 6.6 gallons, nearly twice the size
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:19:02 PM
Quality hardware was included of course
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:21:31 PM
The stock or petcock was not reused. It is a more complicated affair that uses engine vacuum to keep open. This one is a simpler on/off/reserve that requires operators to turn off when sitting for longer periods of time
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:23:59 PM
Then I temporarily mounted the tank up
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:25:50 PM
With the bike leveled up I taped of a 1" wide strip where I planned to mark off the fuel quantity, one gallon at a time
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:28:58 PM
Then with trusty sweet-tea pitcher in hand I filled with one gallon of water and poured it in

I had to darken the water with some milo human poison compound, which did the trick


Cool all graduated up!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:31:04 PM
Then after draining the water, I installed a second petcock. The second will attach to nothing, but be a handy spot to get a little fuel for a camp stove or something like that in the future
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:32:24 PM
Then I simply bolted it back on, then topped it off with the new sergeant seat
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:33:58 PM
This seat is meant to hold a posterior in comfort for many more miles than the skinny stocker
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2014, 04:34:52 PM
And that would conclude a short and sweet build day 5 on the DR
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 02, 2014, 11:47:34 PM
How is the power with the exhaust?

Wanated ask about the headlight too, love the LED.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 03, 2014, 07:46:39 AM
I haven't ridden it very much, knee really just started bending enough to test it out some.
Behind me, there are a bunch of development (Read dirt trails) which I hit last night. I think I need one less counter tooth sprocket, but I could loft the front wheel with power alone in 1st, and even is second for a short bit.

I think the stock bike is a squeamish 37 HP. With the exhaust and no carb or air box mods, I want to stay that the power stays about the same, but with better throttle response. I don't know the bike well enough to make that judgement.

I really only added the exhaust early on because as I kit out the back end, I wanted it's physical presence.

Almost all at once the engine is going to undergo a huge change. I planned the air box mods, the 40mm pumper carb, the 790 cc big bore kit, stage2 cam and a new big valve ported head.

I think that motor might get into the 60 hp range but safely in the upper 50's for sure. The idea is to build it in stages, doing power last of all. The concept is never trying to keep up with that crazy son of mine, nossir, that will never happen, but to be able to low RPM craw up and down stuff with torque when in the scout mode.

Way back when, He (Little Don, the guy who posted the BC trip up), was really just getting started riding a Honda F2 600, I had a Buell S1 Lightening. I was 30 something and he was, I don't know, like 18. We went on a ride together. I can only remember seeing him a couple times...as in tail lights in the distance...yea

Then he went on to some superbike school, then he raced for seasons on a 600 cc F3 all over the left side of the rock, then this and that...wars, moving, jobs, and things which brings us to the present. No I'm quite certain he wrings 155HP worth of performance out of that 70HP bike he has!
Title: Re: DR-650 Build Thread Part 1
Post by: turn_one on October 03, 2014, 03:35:44 PM
^^^Ha!  I remember that ride.  I thought you were just being humble, taking it easy on me.

Anyone can go out and by a 60+ hp 690, tougher to wring 50-ish out of a DR.  Knowing my father there'll be some belt-driven supercharger hangin off that thing in no time.

Regarding your bikes durability, I found that flats are very common and happen often and inopportune moments.  Couple of solutions are:

Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 03, 2014, 03:46:08 PM
Yea...I was indeed thinking about that...Remember changing and patching tubes all the time on an ancient bultaco I had

Tubeless is the way I was thinkin...

But that foam insert thang sounds interesting.

Hey, why don't you pick the tires, tire size and inner tube thing

Something I don't have to think about

Oh and the dyno curves I have seen on these 790's are upper 50's with a stock head. head work and cams adds 10 or more...so I'll be knockin on the door, then with that little whistler, I'll be knockin on the sound barrier!
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on October 03, 2014, 10:26:36 PM
Knowing my father there'll be some belt-driven supercharger hangin off that thing in no time.


The Vet based charity I am part of did a Victory and Indian motorcycle demo event to raise money. One of the bikes had a turbo hanging off the side. In 3rd gear you had to lock your foot under the brake pedal before the turbo lit off or there was a possibility of you becoming a free falling object off the back end. One of the mechanics BARELY kept his helmet from becoming an air-launched object.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:37:01 PM
Name of the day is Cogent...as in Cogent shocks. A good ole American North Caroling firm, they are the experts on DR650 suspension woes. With a very strong set of motor-cross front forks eliminating the weaknesses of that poor performing front ends on these bikes, I only needed help with the rear suspension to get that all in order.

Cogent builds a weight specific coil-over custom valved shock from an Olin unit that is nearly impossible to improve upon. With that all in mind, a couple weeks ago I speced out that shock with the mission weight of the bike and my considerable heft and they built it for me.

Here it is:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:37:53 PM
Here's the victim and the start point:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:39:40 PM
Removal requires the unbolting of the lower scissors linkage and some well shrouded bolts and nuts
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:41:08 PM
To get to this point takes a bit of work, but no too awful bad
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:41:54 PM
Stock air box next is removed to gain access to the upper shock bolt
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:42:37 PM
Yielding this:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:43:54 PM
The upper bolt comes out easily, and here is a comparo shot of each shock
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:45:15 PM
Looks a little barren in there:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:46:54 PM
I used thread locker on the hardware during reassembly, and I also repacked all the needle bearings with fresh synthetic grease
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:48:22 PM
With some struggle, the shock fell back into it's happy place
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 04, 2014, 04:51:55 PM
Then the air box, seat and side covers to complete the task

I did get a chance to work it a little on a area of ground being developed at the moment. Nothing but uneven ground and holes everywhere. That shock worked great. With my still bad knee, I couldn't do a lot of standing, so I putted around while sitting, and the ride was not so bad. Big difference from stock to Cogent!

Thanks to Procycle for supplying the parts!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 06, 2014, 03:14:10 PM
So the after market shock looses the remote reservoir and does a better job? I see the better spring which may account for some of that. My reworked shock keeps the remote.

I thought you were going to do the airbox when you had it!!!

It really needs tires now, it just doesn't look right now. Super heavy duty tubes and Slim,,,,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 06, 2014, 09:24:14 PM
So the after market shock looses the remote reservoir and does a better job? I see the better spring which may account for some of that. My reworked shock keeps the remote.

I thought you were going to do the airbox when you had it!!!

It really needs tires now, it just doesn't look right now. Super heavy duty tubes and Slim,,,,,,,,,,,,,,,
JR,
I had quite the conversation about that shock.
Cogent is adamant that the reservoir is not needed. The shock I bought is the exact one they use on their own DR's.

They offer a reservoir shock for a few hundred more, but they said the only reason they offer them is because people think they need them since the factory unit has a reservoir.
I can return it if it doesn't work...

But so far I really like it

As for tires...I was going to go up to 18" in the rear, that is until I saw how much a wheel is. So I think I'll just be holding at 17" and the front motorcross wheel which is not stock.

Little Don has suggested some tube options and a tire.

I am open to suggestions. The stock rear tire is maybe 60% but I could replace. I would want something larger to accommodate all the torque that 790 will be making
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 07, 2014, 09:58:45 AM
Teaser...A short view into the future:
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on October 07, 2014, 11:23:37 AM
Teaser...A short view into the future:

I cannot begin to say how much I hate that camo pattern (colors)....Not that it's on your bike, just hate that pattern (colors) in general. Never seen it blend in anywhere, well except gravel parking lots or certain couch patterns from the late 70s-early 90s.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 07, 2014, 12:51:01 PM
OK, Bobby doesn't like it

I think I owned one of those couches!

Well, I do, that's 1/1 so far  ;D
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:09:45 AM
Let's get some more done here

Found this pesky thing hidden away inside that cool muffler
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:11:04 AM
Time for some disassembly before the next round of mods
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:13:44 AM
Reading about LD and his trusty sidekick (or is it the other way around??) Brett and them fishing around for used coke bottles in the trash to carry some extra gas. I felt confident that an extra 1.75 gallons of go juice might be prudent

I experimented with painting the can up
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:16:48 AM
It all came out pretty ugly, so I decided to keep it that way for now!

The tube contains some questionable vinyl decal material I am thinking of using for the bike...The order was all botched up and I ended up complaining and the vendor ended up giving it to me for free since it had already been shipped, so admittedly, I feel sorta wrong using it in the first place.

But it was a part of the concept so since it's here, I decided to give it a try
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:18:54 AM
I covered the rear fender first.

The stuff is not at all easy to use. It takes heat to get it to conform to curves and it wants to leave air blisters and wrinkles all over the place.

Given that I am not that interested in a "Good Look" per see, but rather getting the thing ghosting into the background, I went with it and proceeded
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:20:56 AM
Next, This nifty cargo rack was bolted up. It will carry a fuel can and a soft bag filled with stay dry, stay fed, and stay warm stuff
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:23:00 AM
The Roto-Pac system uses these stout aluminum bases to click and secure the fuel or water tanks
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:23:45 AM
The ugly gas can fits like this:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:25:39 AM
The ugly cammo spreads...I don't think I am liking it much....
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:26:30 AM
...And spreads...
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:37:55 AM
And continues to cover up the tank:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:45:27 AM
You might have noticed that I did not cover the front fender or the headlight plastic thing.

That's because I am not sure I want to keep this stuff on the bike...

Time will tell as I season my decision here and evaluate this questionable product
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2014, 09:48:23 AM
Well, since applying the stuff, I have been watching it peel off and delaminate.

Here's a hint: I went out and purchased several cans of flat camouflage paint...

No decision made yet...
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 20, 2014, 03:11:16 PM
It is not so much the paint you get but the primer. There is the Fusion paints made for plastic that work OK.

Then you have Bulldog primer made to use with any paint.

You need to paint the muffler,,,,,,,,,,,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 20, 2014, 03:32:56 PM
I have that bulldog adhesion promoter

I'm not liking the overall poor quality of that camouflage vinyl junk.

I think it is coming back off and the bike will get a more conventional painted on camo pattern

So, the muffler needs to be black, eh??
Title: Re: DR-650 Build Thread Part 1
Post by: cudakidd53 on October 20, 2014, 09:37:38 PM
You can do a better job spraying Don!  Vinyl wouldn't hold up with gas and brush busting tearing it up.  You can also spray through mesh to give it small textural over-spray pattern after you give it a free spray, base pattern, can job.  :o
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 20, 2014, 09:57:04 PM
I'm still thinking about that black muffla...
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 21, 2014, 12:05:12 AM
Camo bike, shinny muffler, thumbs down.

BBQ paint, easy to repaint when scuffed. Works on gun parts, why not a hot muffler.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 25, 2014, 10:21:59 PM
Camo bike, shinny muffler, thumbs down.

BBQ paint, easy to repaint when scuffed. Works on gun parts, why not a hot muffler.

Just picked up some John Deere tractor muffla paint

Gonna ghost up that muffla some

And pull off that horrible vinyl

Do yourself a favor and don't ever buy that trash!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 12, 2014, 07:35:14 PM
It's been a couple weeks since applying the vinyl. It is peeling loose in many places. It looks awful. I just imagine what it would look like flappin' in the breeze collecting dirt all over the exposed adhesive.
This stuff is terrible, don't use it!
I'm going to tear it off!
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on November 12, 2014, 08:48:58 PM
It's been a couple weeks since applying the vinyl. It is peeling loose in many places. It looks awful. I just imagine what it would look like flappin' in the breeze collecting dirt all over the exposed adhesive.
This stuff is terrible, don't use it!
I'm going to tear it off!


I thought you'd already removed it and continued on with the spray paint idea.
Title: Re: DR-650 Build Thread Part 1
Post by: turn_one on December 18, 2014, 04:47:17 PM
Chief!

How's the big DR sitting on projects?  Big bore? Knobbies?  Cammo painting?  Trade for KTM 690?

We must know...

Chrome is puke, agreed, but painting a muffler will look good until your first serious ride at which point it'll look like muffler painted black with chrome highlights.

Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2014, 05:06:56 PM
I was sort of thinking the same thing.
Plan is to remove that horrible vinyl, then just OD green the sucker
Performance project this winter is probably just the 40mm Pumper carb, get it up to 300 HP or so.

I'll add the rear bags, tank bag, windshield, and a gun rack somewhere.

Right now, in pre-knee mode, I am working trying to make SquareD a roller repleat with engine and trans...Then the surgeons can have their way. It gets longer springs after I get better, then I'll mess with the bike some. Will have it ready for some early spring riding to sort it out some.

690 would be nice!
Title: Re: DR-650 Build Thread Part 1
Post by: turn_one on December 18, 2014, 05:15:49 PM
Reading about SquareD and the trans build now.

Tough to get excited about bikes when it's 40's and raining all the time but I'm sure the DR will be breathing fire once you get your stoke back for it...and a working knee.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2014, 08:59:48 PM
Reading about SquareD and the trans build now.

Tough to get excited about bikes when it's 40's and raining all the time but I'm sure the DR will be breathing fire once you get your stoke back for it...and a working knee.
I know what you mean! Hard to get excited about the truck as well when the garage is a comfortable 32F!
Title: Re: DR-650 Build Thread Part 1
Post by: turn_one on December 20, 2014, 01:47:20 AM
What?? No heat in that garage?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 20, 2014, 11:16:13 AM
What?? No heat in that garage?

Well I have the torpedo heater when it's working...but I get the fumes. hing is I like to work in the cold, say 45-50 is just fine to keep the wrenches flying and the torch sparkin'
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on December 20, 2014, 11:18:28 AM
Thing is I like to work in the cold, say 45-50 is just fine to keep the wrenches flying and the torch sparkin'

Well you could always migrate up here and work in the cold for a decent chunk of the year.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 20, 2014, 11:25:49 AM
Thing is I like to work in the cold, say 45-50 is just fine to keep the wrenches flying and the torch sparkin'

Well you could always migrate up here and work in the cold for a decent chunk of the year.
Thanks anyway Bobby!
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on December 20, 2014, 11:53:26 AM
Lol don't be scared of the cold. Lol it'd wear Sled dog and Red dog out fast.
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on December 20, 2014, 12:00:59 PM
Garage is insulated I would suspect. Go find a 4-5 kW electric 240 volt heater. Everywhere should have some form in that ballpark (even HF may at times) you're a 30 amp circuit from comfort. If you can't find one that size a couple 1500 watt ceramic heaters would take the edge off.

Before I got my proper heater I was using a little car warmer, 700 watt or so. Single garage but it would do the job down to about -20 or so. Not warm but in the 50 range. So I'm thinking you should be able to do something fume free.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 20, 2014, 12:06:36 PM
Garage is insulated I would suspect. Go find a 4-5 kW electric 240 volt heater. Everywhere should have some form in that ballpark (even HF may at times) you're a 30 amp circuit from comfort. If you can't find one that size a couple 1500 watt ceramic heaters would take the edge off.

Before I got my proper heater I was using a little car warmer, 700 watt or so. Single garage but it would do the job down to about -20 or so. Not warm but in the 50 range. So I'm thinking you should be able to do something fume free.
Good idea...

I have the torpedo heater burning diesel that works fine.
The area is big 36 X 28 X 15-18 feet tall...lots of volume

I do have an extra 30 amp 220 v receptacle  and I have a HF nearby...
Title: Re: DR-650 Build Thread Part 1
Post by: Nate on December 20, 2014, 12:12:37 PM
I have to say, i am definitely not a fan of the air force camo pattern.  as far as the exhaust paint job, have you thought about a shaker can of auto engine/exhaust paint?  i think they are rated to something like 1200deg.  something like this http://www.eastwood.com/por-15-hi-temp-aerosol-flat-black-44118.html
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on December 20, 2014, 12:17:05 PM

Good idea...

I have the torpedo heater burning diesel that works fine.
The area is big 36 X 28 X 15-18 feet tall...lots of volume

I do have an extra 30 amp 220 v receptacle  and I have a HF nearby...
[/quote]

I knew you're garage was proper size, but dang you sure did it right at that size.
One other thing that will help out is a small fan or two circulating the air back from the ceiling. You end up with nice even heat distribution.
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on December 20, 2014, 12:17:39 PM
I have to say, i am definitely not a fan of the air force camo pattern.  as far as the exhaust paint job, have you thought about a shaker can of auto engine/exhaust paint?  i think they are rated to something like 1200deg.  something like this http://www.eastwood.com/por-15-hi-temp-aerosol-flat-black-44118.html

I've used this and I like it.

http://www.oreillyauto.com/site/c/detail/VHT1/SP102/N0797.oap?ck=Search_N0797_VHT_-1_-1&mn=VHT&mc=VHT&pt=N0797&ppt=C0171
Title: Re: DR-650 Build Thread Part 1
Post by: JR on December 23, 2014, 01:15:30 AM
Although it was a nice 69 today it was hanging in the low 40s a week ago. I have one of the HF propane heaters and it does good even with the door open. Right now I use a little 1000w dish electric that will keep it at 60 with the door closed.
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on February 24, 2015, 04:40:52 PM
So did DR go the way of Big Red, and TacGator? Pushed into the cold, lonely corner, to be forsaken until one day, the pile of D2 boxes; slowly drawn down from the mountainous range they have assembled into; allows the warm rays of sunshine to creep across the garage floor to slowly re-awaken DR and bring her to all her off-road glory?

Or you still working on plans for her?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on February 24, 2015, 08:24:59 PM
So did DR go the way of Big Red, and TacGator? Pushed into the cold, lonely corner, to be forsaken until one day, the pile of D2 boxes; slowly drawn down from the mountainous range they have assembled into; allows the warm rays of sunshine to creep across the garage floor to slowly re-awaken DR and bring her to all her off-road glory?

Or you still working on plans for her?
The red dog marked it...

Right now it is warm and cozy in a corner of the garage. Ever since the dogs marked it, no one has interest in it (Including me). When I get a break in the action I plan to pull it out and strip all that horrible decal stuff off of it, then get to the OD green paint scheme.

For this year I'm rolling with the current config plus a 40mm pumper carb and start to use it to see where the problems (if any) lie. I want it a part of the entire B.O. package for all the reasons stated already. So, ya, it is around lurking in the shadows of SquareD
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:43:10 PM
It's been awhile since I cracked a wrench on the DR.

Today a buddy of mine showed up for the third time asking me to go riding with him. I felt so convicted that I started on the bike once again.

It was completely destroyed by a heavy layer of dust. I could barely salvage anything!

Beneath the dust was that horrible useless, waste of time and money vinyl condom that was pretending to be a quality digital camouflage.

I started pulling it off, and just like that the dust came off as well!

I was able to save the bike!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:44:07 PM
I pulled it off the side covers as well
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:45:26 PM
Then I started getting a little crazy. Since I was tearing things apart, why not paint them I sez to meself. So I scratched the plastic side covers down with 1000 grit
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:46:23 PM
Then sprayed on some Bulldog Adhesion Promoter
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:47:23 PM
Then I started turning things green
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:48:58 PM
Since those got all green and tactical, I cast my glance upon that large fuel tank

Turned that sucker green as well
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:50:11 PM
I put the bat charger on to the smallish battery and started digging up parts
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:51:13 PM
The rear fender is going to have to come back off so I can get the condom off of it as well
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 24, 2015, 10:52:24 PM
After a few hours drying time, the plastic pieces/parts were looking very Ranger-like
Title: Re: DR-650 Build Thread Part 1
Post by: Dawg25385 on August 24, 2015, 11:10:23 PM
The OD is much better then those decals. Maybe a couple old school army stars on the fuel tank? Just an idear...


Sent from my iPad using Tapatalk HD
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 25, 2015, 08:22:57 AM
The OD is much better then those decals. Maybe a couple old school army stars on the fuel tank? Just an idear...


Sent from my iPad using Tapatalk HD
Ya know...

I am going to stick my uniform patches on the side covers.

In the Armee we wear the unit we are assigned to on the left shoulder.

We wear the unit we were in combat with on the right shoulder.

So I'll wear the 101st Airborne on the left and USASOC (United States Army Special Operations Command) on the right side cover
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 25, 2015, 10:34:46 AM
That looks better. I like the patch idea.
Title: Re: DR-650 Build Thread Part 1
Post by: Dawg25385 on August 25, 2015, 10:57:16 AM
No Night Stalkers patch?

(http://i.imgur.com/2BFXAyG.png)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 25, 2015, 11:32:23 AM
No Night Stalkers patch?

(http://i.imgur.com/2BFXAyG.png)
That is not a "Unit patch" per-see

It is the 160th's or the 1st battalions patch they might wear on the right chest (If they wore patches, which they don't)

The 160th unit patch is the red one with the sword, or USASOC

I could put that patch you showed along with several others I have on the bike and make it look like Maverick's Ninja or flight jacket in Top-Gun, but not really what I want to do
Title: Re: DR-650 Build Thread Part 1
Post by: Dawg25385 on August 25, 2015, 11:34:48 AM
No Night Stalkers patch?

(http://i.imgur.com/2BFXAyG.png)
That is not a "Unit patch" per-see

It is the 160th's or the 1st battalions patch they might wear on the right chest (If they wore patches, which they don't)

The 160th unit patch is the red one with the sword, or USASOC

I could put that patch you showed along with several others I have on the bike and make it look like Maverick's Ninja or flight jacket in Top-Gun, but not really what I want to do

Ahh.. sorry i have no clue how it all works.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 25, 2015, 11:45:31 AM
The one I wore is the original blue circle

The unit crest is a smaller metal medallion worn on the shoulder epaulets and above the unit awards on the right chest
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 25, 2015, 01:42:01 PM
I think we will start calling you OD vs BD.

Or would that be ODD,,,,,,,,,,?

Did you spray the red dog?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 25, 2015, 05:06:45 PM
I think we will start calling you OD vs BD.

Or would that be ODD,,,,,,,,,,?

Did you spray the red dog?
I sprayed her with the sand blaster the other day...Does that count?
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 25, 2015, 06:27:56 PM
Close enough, Olive Drab Don,,,,,,,,,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 25, 2015, 08:33:10 PM
Close enough, Olive Drab Don,,,,,,,,,,,,,,,,,,,,
Nope, didn't camo up the dog, although it's an interesting idea

I couldn't work on the bike today due to many other commitments, and besides this old school paint was not completely dry

I untaped the fuel tank and let things sit
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 25, 2015, 08:41:44 PM
The OD is much better then those decals. Maybe a couple old school army stars on the fuel tank? Just an idear...


Sent from my iPad using Tapatalk HD
Ya know...

I am going to stick my uniform patches on the side covers.

In the Armee we wear the unit we are assigned to on the left shoulder.

We wear the unit we were in combat with on the right shoulder.

So I'll wear the 101st Airborne on the left and USASOC (United States Army Special Operations Command) on the right side cover

Don, edumucate some of us that never served.

How is it you are assigned to one unit and go combat with another?  And what patch do you wear if you went to combat with two different units?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 25, 2015, 10:04:11 PM
The OD is much better then those decals. Maybe a couple old school army stars on the fuel tank? Just an idear...


Sent from my iPad using Tapatalk HD
Ya know...

I am going to stick my uniform patches on the side covers.

In the Armee we wear the unit we are assigned to on the left shoulder.

We wear the unit we were in combat with on the right shoulder.

So I'll wear the 101st Airborne on the left and USASOC (United States Army Special Operations Command) on the right side cover

Don, edumucate some of us that never served.

How is it you are assigned to one unit and go combat with another?  And what patch do you wear if you went to combat with two different units?
You might have served with the 82nd airborne during an assignment where they were deployed to a combat theater.

Afterward, let's say the Army reassigns you to the 10th Mountain Division. In this example you would wear the 10th mountain patch on your left sleeve, your unit of assignment, while wearing the 82nd patch on your right sleeve.

If you are wearing the same patch on both sleeves, you are said to be a _____ cookie  101st cookie, 1st Infantry division cookie, and so forth

If you have multiple combat patches (Which I do) then I suppose it's your choice. I went to Panama in 1st SOCOM (Special Operations Command) which has the "Electric Horse" Lightening bolt Special Forces patch.
I served another Combat tour in USASOC (United States Army Special Operations Command) which has that upward sword. Both were Airborne units. I wore the electric horse on older BDU's and the later USASOC patch on later uniforms. Almost had a 101st Combat patch, as I was the flight Lead for the Haiti invasion, which turned out to be a big Kum-by-ya something or another.

I wanted that 101st combat patch
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:36:13 PM
Had a couple extra hours left over today so I decided to get a couple things done on the bike as well as Red and Square D.

First I mounted up the new windshield
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:37:44 PM
Then I got busy making a bigger "Foot" on the kickstand
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:38:44 PM
It didn't affect lean angle all that much and it should provide more stability
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:40:07 PM
Next I pulled the front and rear plastic in preparation for painting OD Green
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:42:06 PM
And made those Army Green to match everything else I own!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:43:32 PM
I fitted up the fuel tank for a moment to see how all that looks. Ahhh, I think I like it, but undecided at the moment
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 14, 2015, 10:45:26 PM
I ordered a new super motorad front fender for the bike which will steer better at speed on the highway, but allow some more mud to get digested by my face. I'll pull the existing fender when it shows up
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:05:31 PM
Started reassembly today

First part on is the exhaust guard
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:06:26 PM
You may recall I had to cut the wires to the taillight to be able to remove the rear fender:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:07:58 PM
Here they are reconnected and covered with heat shrink tubing
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:08:44 PM
And the rear fender goes back on
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:10:51 PM
This thing didn't have a fuel filter, well, not a "Normal" in line unit. So I grabbed one off the shelf, this one is a briggs and Stratton to now serve proudly on the Recon DR
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:12:28 PM
I just cut everything in half, using the factory hose, added in the filter and two new hose clamps and hooked it up
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:14:05 PM
OK, with that done, on goes the 6.6 gallon fuel tank

I didn't like the supplied hardware and opted for fender washers to hold down the tank instead
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:16:58 PM
Then the front headlight guard thing and the new windscreen
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:18:05 PM
Rear rack and side covers checked for fit...all good so far
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:19:11 PM
Then that great Sargeant seat and the roto-pac fuel can
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:19:54 PM
Next up, this small factory tool kit holder is going bye-bye
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:20:59 PM
I'll anchor a new 3" PVC tube to the frame using this strap of aluminum
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:22:02 PM
I won't be using a helmet lock, so I sawed that thing right off the frame...saved about 19 pounds!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:23:42 PM
Test fit seems to be fine
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:24:48 PM
I coated it with bed liner and allowed it to dry while I worked on Square D
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:28:19 PM
Then I put it all back on the bike
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 08:31:13 PM
It turned out OK me thinks!
Title: Re: DR-650 Build Thread Part 1
Post by: Dawg25385 on September 15, 2015, 08:43:49 PM
Lookin pretty good there chief. Good call on the PVC pipe storage compartment.


Sent from my iPhone using Tapatalk
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on September 15, 2015, 08:52:12 PM
Looks great !! I also like the storage pipe. What did you use for the end cap/plug ?. I don't remember it being mentioned.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 15, 2015, 10:01:41 PM
Looks great !! I also like the storage pipe. What did you use for the end cap/plug ?. I don't remember it being mentioned.
In the plumbing section it is a test plug used to pressure test a PVC system. Costs around $8 and works great
You can get them in 4" size as well. Makes a great water and air tight temporary storage for anything. I plan to mount one or two in both trucks and on the track loader to store things I don't want getting corroded.
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 15, 2015, 10:09:44 PM
I see the problem straight away...sitting down on the job.  At least you weren't wearing the mandals
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 16, 2015, 09:47:22 AM
I see the problem straight away...sitting down on the job.  At least you weren't wearing the mandals
I only wear them when I'm welding!
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 16, 2015, 10:09:26 PM
Sounds like me.  I found that barefoot is about as effective as my New Balance mesh shoes.....
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 17, 2015, 12:46:41 AM
Nice updates and upgrades! I like the color and the window on the tank, remember when you scaled it out.

I was really hoping to see a weatherpack on the rear light wire though.

Does the BD seat fit the BD er, posterior?
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on September 17, 2015, 02:59:40 AM
Start it up... err wrong thread? I think..
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:06:31 AM
Nice updates and upgrades! I like the color and the window on the tank, remember when you scaled it out.

I was really hoping to see a weatherpack on the rear light wire though.

Does the BD seat fit the BD er, posterior?
Yup, that Sergeant there fits me just fine!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:40:25 AM
New parts

Super moto front fender
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:48:32 AM
I was working all day cleaning the garage, but when the box showed up, I had to play a little!

That got painted green, but I forgot to take a pic!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:50:57 AM
Some more stuff
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:52:48 AM
Stock mirrors are no good, so this one went bye-bye

Funny, but I thought I purchased two of them!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:54:17 AM
Slowly but surely...
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 17, 2015, 01:41:11 PM
Hey, make the PVC tube a weapon, it kindo looks like a chaff launcher.

Make it a potato launcher, think I just saw that somewhere.

Does it run??? Its purdy
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 02:58:25 PM
Hey, make the PVC tube a weapon, it kindo looks like a chaff launcher.

Make it a potato launcher, think I just saw that somewhere.

Does it run??? Its purdy
Yep, this one runs
Rode it a couple days ago
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 17, 2015, 08:44:42 PM
Don, other than looking more ninja like, what are the benefits of the new fender?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:43:00 PM
Don, other than looking more ninja like, what are the benefits of the new fender?
It is said that at highway speed the MX style fender tries to steer the bike, sometimes in the direction of the wind (Crosswind)
The ninja fender eliminates this, albeit at the cost of reduced mud splash protection. I am not sure the ninja super-moto fender will stay. More of an experiment really
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:44:42 PM
Speaking of which, when I awoke this very morn, my knee was all swollen, so I decided to take it easy on it and work from a chair instead of crawling all over SquareD. So I worked a bit on the bike instead.

Here's the new and old fender
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:46:00 PM
I pulled the fender off which gave me access to the oil cooler. I will be replacing this rock guard with something a bit more substantial
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:47:23 PM
The factory wire mesh cannot handle sharp sticks and bigger flying stones, but this stamped steel guard can
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:48:05 PM
Fits like it belongs there
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 17, 2015, 10:48:10 PM
Sorry to hear about the knee,big D.  rest it.  We are getting too old to just "power through it"
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:49:11 PM
Then with 4 carefully drilled holes, the ninja fender is bolted home
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:51:40 PM
The factory shifter folds a little, but not enough. When dropping the bike, the shifter is shoved rearward highly stressing the shifter rod and engine case. This aftermarket shifter prevents most of that due to it's design
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:53:37 PM
While messing with the shifter, I decided to mod the countershaft sprocket cover. It is closed off and allows crud to accumulate in there. A hole is needed to be able to flush out mud and gunk
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 10:59:19 PM
And this is how all that fits and works
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 11:01:20 PM
Another problem solver mod is the removal of the bottom chain roller. It is a factory single shear chain roller thing that does nothing except to crack the frame at some point in the future. Therefore most folks (Me included) just remove it and discard it.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 11:03:05 PM
Not liking the kink in the fuel line, so I ordered a filter with a 90 degree outlet. I also ordered a 40mm carb with an accelerator pump, known as a "Pumper" which I will install maybe this weekend and get this fuel line thing sorted out
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 17, 2015, 11:04:01 PM
Finally, on my "Easy" day, I undercoated the new kick stand foot I had welded on
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:47:57 PM
The hosting company moved this web site over to our own server to accommodate our growth. When they did that they dumped a lot of photos, like all those missing in the preceding posts
GRRRRRRR.......
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:51:10 PM
Babying my knee still, I decided to get some more done on the bike since I work while sitting in a chair.

Today's project is to install a 40mm "Pumper" carb. Because it has an accelerator pump and slides vs butterflies, the thing is supposed to run a lot better. It is said to be the single biggest performance mod for this bike.

Here is the sparkling new Mikuini:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:52:07 PM
It has a built in choke knob so the cable to the handlebar can go bye-bye
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:54:10 PM
It comes with a new set of throttle cables and some extra jets for custom tuning. The carb was sent to me already jetted for the big pipe, and the air box mod along with the K&N filter it will be getting
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:54:34 PM
Before the teardown
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:56:48 PM
The tank, side covers, seat and a few do-dads need to be removed to get working room. then the carb is unclamped and the throttle and choke cables are removed
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:58:14 PM
This is the "Snorkel" and the source for the air this bike breathes. Sort of small...It will find a new home in the trash can
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 10:59:16 PM
There are a host of parts like this air filter/breather which will not be reused
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:00:44 PM
After unbolting the air box and moving it aft a little the carb is slipped out of it's mount, never to return
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:01:36 PM
New and old
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:03:10 PM
The master cyl is pretty small, but is in the way, so it gets moved
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:04:29 PM
The carb mount on the head has some rubber tabs which need to be trimmed away
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:05:53 PM
Then I pulled the stock Air Box to modify it
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:07:38 PM
Out comes the stock air filter

And gets installed in the trash
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:09:00 PM
The snorkel is pulled next
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:10:44 PM
Then, using the cutout template a hole is cut in the top of the airbox which greatly enhances airflow
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:12:38 PM
In goes the K&N

I'll try this for a little while, then place a foam wrap over the filter
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:13:57 PM
Being an on/off road bike, I left the FOD screen intact
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:15:46 PM
Then the new carb and the air box is installed
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:17:07 PM
Then the old throttle cables were replaced with the new ones
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:18:34 PM
The cables are hooked up and adjusted here and the air box buttoned up
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:20:54 PM
While I had it down, I an a 8 gage hot wire directly from the battery forward to the handlebar area. This will be used to power lights, a GPS, a cell phone and a charger for the computer. Maybe even some heated hand grips!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:21:51 PM
Here is the stuff which is not reused or has been replaced!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 20, 2015, 11:23:47 PM
And it's all done!

Throttle response is amazing. It's instant on and off. It has a sharp bark to it now, and low RPM is butter smooth. Will get a ride report in the next couple days
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on September 21, 2015, 02:28:25 AM
Looking good. You going to give it a shakedown at the farm? Or is it not farm ready yet?
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 21, 2015, 03:17:13 AM
Great work BD, I have the 39mm for my 600, but used.

Did you do something else for the breather? If for the crankcase you need it.

Sorry bout the knee. My cortisone shots wore off for the ankles, time for a real fix. I was in heaven for a couple weeks.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 08:38:55 AM
Looking good. You going to give it a shakedown at the farm? Or is it not farm ready yet?
It's rideable. Should see a farm trip or two before cold weather.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 08:41:32 AM
Great work BD, I have the 39mm for my 600, but used.

Did you do something else for the breather? If for the crankcase you need it.

Sorry bout the knee. My cortisone shots wore off for the ankles, time for a real fix. I was in heaven for a couple weeks.
Yep Cortisone is da bomb, then reality sets back in!
Knee is manageable. When it gets to a certain point, time to back off.
I was giving it 30 min on the tread mill, then working around for a full day, then pulling guard at the church until 2300. That's what pushed me over the edge. All better now, heading over to do coatings on Sarge and see how the hydraulic line repair is shaping up.
Found a trucking company to move it!
Title: Re: DR-650 Build Thread Part 1
Post by: cudakidd53 on September 21, 2015, 04:09:05 PM
Really nice work!  Suggestion: Keep old parts for SHTF spares- price is right!
Title: Re: DR-650 Build Thread Part 1
Post by: Dawg25385 on September 21, 2015, 04:24:24 PM
...then pulling guard at the church until 2300.

Mind if i ask what your kit is when you're on guard duty? G23 and 2 spare mags?

Hope your knee gets better as well!
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 21, 2015, 08:58:55 PM
Claymore inside a bag of pork rinds.....

Don, looks great.  Might consider a screen over the new larger airbox opening?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:27:12 PM
...then pulling guard at the church until 2300.

Mind if i ask what your kit is when you're on guard duty? G23 and 2 spare mags?

Hope your knee gets better as well!
Usually, yes
Sometimes I switch to the G19, 2 mags (More rounds)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:30:54 PM
Got a bit more done on the bike today. First I took it on a ride. Darned thing rides nice! Has a lot of low end grunt, heck with a big 650cc lung hammering away, it's gonna have torque everywhere, and it does!

Picked up this cool cross-over helmet. Has dual sport friendly stull like visors, two of them, a clear and a smoked one, and the all too necessary visor as well.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:31:58 PM
Adjustable vents everywhere!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:33:38 PM
Outside clear visor in a grab and shut affair

Inside smoked visor is controlled by a button/slide on the side
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:34:59 PM
Great construction and a great latch system which is easy
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:36:03 PM
First thing I did was to change the oil. I replaced the factory drain plug with a magnetized one
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:37:00 PM
Then I placed a circular magnet onto the oil filter
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:37:55 PM
Nothing radical for oil, just a good grade dino for this steam engine
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:39:56 PM
I'm a big guy, so I need to make everything I own bigger. First step here is to raise the handlebars an inch. I'll be removing these standard height risers and replacing them with some taller units
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:40:45 PM
I got these in the mail, but wouldn't you know it, they were the wrong size!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:42:04 PM
So I got on the phone to Pro Cycle in Oregon and they had new ones headed my way in an hour! Great people in that company!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 21, 2015, 10:43:12 PM
Not liking those tires...

Don't like the ninja fender either...too small. So I painted up the stocker and it will be going right back on!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 07:48:48 PM
Say bye-bye to the praying mantis lookin' fender

Some smart guys over at DR Riders said it was a useless thing unless you liked eating mud
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 07:50:31 PM
So the old stocker has been properly militarized and will get the addition of a strut or stiffener. I plan to carry a little bag on top of the fender so this will help support the weight
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 07:51:29 PM
Has a bit of spring in its step it would appear:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 07:52:52 PM
I think I'll drill that and stick in a couple more screws

On to the handlebar risers. Fitting this thing to a big guy, this is step one

These risers will set the bar up another inch
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 24, 2015, 08:11:32 PM
I like the old fender Don and the plate looks good.  I assume thats a commercially available piece?

Raising the bars is easier than replacing them, trust me.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 08:16:07 PM
You can see the difference in heights
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 08:18:05 PM
All buttoned up

I took it for a ride afterward and I definitely like the new bar position
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 24, 2015, 08:19:05 PM
These are next. I'll either purchase lower pegs or just cut these up and reweld the pegs mucho lower
Title: Re: DR-650 Build Thread Part 1
Post by: Flatlander on September 24, 2015, 09:35:52 PM
Any option of rotating bracket 180° as well as foot peg?

FL
Title: Re: DR-650 Build Thread Part 1
Post by: Flatlander on September 24, 2015, 09:49:01 PM
sorry, scratch that option. keep the pegs above the lower frame rails!
LOL, What the heck was I thinking?

FL
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 24, 2015, 10:07:11 PM
yep, don't want the foot to low. You will pay in turns and when you sink it.
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on September 25, 2015, 06:38:38 AM
Don, is the knee getting better?
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on September 25, 2015, 08:34:24 AM
Original fender is definitely better. The stiffener should help a lot too.
Looking great, is the power sufficient to not do the big bore?
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on September 25, 2015, 10:30:59 AM
...and one more question from the lowest DOT...you sure that fender brace doesn't go below the fender? looked kinda funky from here.
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 25, 2015, 11:42:37 AM
...and one more question from the lowest DOT...you sure that fender brace doesn't go below the fender? looked kinda funky from here.

I thought thee same. Its a stiffener not a mount.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 25, 2015, 07:54:11 PM
Don, is the knee getting better?
Knee was FMC a week ago.
All that standing around wile helping at the "99" is what did it
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 25, 2015, 07:55:49 PM
Original fender is definitely better. The stiffener should help a lot too.
Looking great, is the power sufficient to not do the big bore?
I gotta say, power is pretty good for a one lunger! No race bike, but it will get right along. I think for a survival bike build it just might be adequate...But I HATE leaving anything alone. Why leave stuff the same when you can "Fix" it mo-better???
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 25, 2015, 07:57:16 PM
...and one more question from the lowest DOT...you sure that fender brace doesn't go below the fender? looked kinda funky from here.

I thought thee same. Its a stiffener not a mount.
Yea, it's GTG
Lots of folks mount a fender bag up on top of it. Same/same as I'm going to do
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2015, 06:19:07 PM
Speaking of a fender bag, it came in today. Pro Cycle in Oregon has been the go to supplier for so many of these parts. I order them and they are here just 2 or 3 days later.

I am using the proven Wolfman fender bag. When I change out the tires, I'll install new inner tubes. I plan to keep the old ones along with a healthy patch kit in this fender bag.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2015, 06:20:46 PM
I'm also "kitting out" the tool kit to include all the stuff I think I'll need along the way

A couple of good tire irons for a dual sport is a downright necessity. These have a wrench end that fits the axle nuts
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2015, 06:21:25 PM
They tuck nicely into the wolfman fender bag
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2015, 06:22:03 PM
Its sort of flat now without the spare tubes, but this is how it fits:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2015, 06:25:45 PM
These Shinko tires are a good tire to learn more on my bike. Made for perhaps 60% street/40% off road, they will be perfect to get me some mileage and will run up and down a trail or dirt road all day plus two nights. Notice how the blocks are slightly further apart than with the stock Trail Wings...Plus the rear tire is a 130, stocker is a 120
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 29, 2015, 06:52:29 PM
You know, that brace looks good with the bolt on it. Now its hidden anyway.

Wolf makes some nice stuff. Those tire wrenches are cool.

I have seen good reviews of the Dunlop 606 and I like the Kenda K270s . What made up your mind on these?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 29, 2015, 11:58:00 PM
You know, that brace looks good with the bolt on it. Now its hidden anyway.

Wolf makes some nice stuff. Those tire wrenches are cool.

I have seen good reviews of the Dunlop 606 and I like the Kenda K270s . What made up your mind on these?
Talking to the Pro Cycle guys, they thought these Shinkos would work well and a big step up from the slippery Trail Wings. Inexpensive as well.
Bridgestone 606's are legendary. So many new offerings these days, it's hard to decide
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 30, 2015, 12:36:53 AM
Yeah the guys love the 606 but they wear fast. But it is a trade off.
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on September 30, 2015, 03:14:10 AM
You're making me want to get a bike like that. No good can come of this.
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on September 30, 2015, 09:58:38 AM
You're making me want to get a bike like that. No good can come of this.
That's what I was thinking. 

Sent from my SM-G900V using Tapatalk

Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 30, 2015, 10:04:20 AM
You're making me want to get a bike like that. No good can come of this.
No, bobby, no good at all!

Hint/Thought: The Marines contracted Kawasaki to build a militarized bike like mine. All OD green of course and get this...Has a diesel engine!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 30, 2015, 10:08:18 AM
Oh, and if you make it down here, just ride mine...but don't gruntize it (Wreck it)

So the Infantry Sergeant locks two of his privates in a room for two hours with nothing other than two stainless steel balls.
He returns, unlocks the door and inspects the scene. There is significant damage to all the walls and the ceiling, both privates are injured, one steel ball is missing, and the other is broken...and nobody knows what happened!
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on September 30, 2015, 11:59:22 AM

No, bobby, no good at all!

Hint/Thought: The Marines contracted Kawasaki to build a militarized bike like mine. All OD green of course and get this...Has a diesel engine!

I'd been wondering why you don't see more diesel motors on dirtbikes/snowmobiles/ATVs and etc. It has to be possible somehow.


Oh, and if you make it down here, just ride mine...but don't gruntize it (Wreck it)

So the Infantry Sergeant locks two of his privates in a room for two hours with nothing other than two stainless steel balls.
He returns, unlocks the door and inspects the scene. There is significant damage to all the walls and the ceiling, both privates are injured, one steel ball is missing, and the other is broken...and nobody knows what happened!

Well how else you gonna know what it can take it you don't push the limits?

It's true.
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on September 30, 2015, 01:22:20 PM
There is an outfit up here working on a diesel (multi fuel actually) snowmobile. Has military intent written all over it. Just noticed they have a contract now...


http://www.dewengineering.com/news.htm

Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on September 30, 2015, 01:22:53 PM
Diesel = more cost and more weight. The military might not care about money as much as weight..?..

The border patrol has a flippin fleet of bikes out here, mostly od, with some being donated ex mil.
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on September 30, 2015, 01:26:51 PM
There is an outfit up here working on a diesel (multi fuel actually) snowmobile. Has military intent written all over it. Just noticed they have a contract now...


http://www.dewengineering.com/news.htm


You can have the snowmobile (even though it's super cool, it still has to be ridden in COLD !!), I'll take the HEMTT farther down in the article.
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on September 30, 2015, 01:30:47 PM
I looked at them quite seriously until I found the top speed in the 25-30 mph range.
That slow plus water and slush equals really stuck.
I'll keep my gas burners that can swim.
And heck I'll say the same for your HOT!

The HEMTT looks pretty good though too.
Title: Re: DR-650 Build Thread Part 1
Post by: JR on September 30, 2015, 02:39:00 PM
Don, check the strap on that front bag. If you bottom out and the straps are across the bottom of the fender it will rip off, or just stop you endo style ;D
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on September 30, 2015, 04:07:45 PM
Don, check the strap on that front bag. If you bottom out and the straps are across the bottom of the fender it will rip off, or just stop you endo style ;D
Copy!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:31:45 PM
I got that part in from Australia today. A bit more than a week to get here from Victoria, AU.

It's a part called a Case Saver which mounts around the countershaft sprocket and prevents a disintegrating chain from damaging the engine case
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:32:27 PM
It replaces this cheapo plastic guard that I modified last week
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:33:40 PM
While I have it down today, I'll add a 14 tooth counter sprocket, the rough equivalent of going from 3.73 gears down to 4.10's
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:34:36 PM
The old sprocket comes off easily
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:35:23 PM
The newer 14T sprocket is a tad smaller in diameter
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:36:10 PM
But fits right on like it was made for the bike!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:37:08 PM
Then the case saver bolts on quickly and easily with just three allen head screws
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 01, 2015, 10:39:30 PM
The 14T sprocket will make the bike even more torque. I didn't test drive it today because of rain. With the stock 15 tooth it would loft the front tire so easily that I can only imagine what it will be like now. Better hang on!

And that is it for a quickie mod for today...time to get the youngin to football practice!
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on October 02, 2015, 12:42:27 AM
Nice Don.  Was a front sprocket change easier or more practical than a rear sprocket change?

Funny story.  About 10 years ago, I rode sport bikes.  I had a fully tricked Triumph Daytona 955i with tweaked ECM, air flow, custom exhaust, etc, etc.

I was riding one weekend out some two lane road in the middle of no where with a friend and I hit 187mph on a long stretch.  Thought I would play Miguel Duhamel and sit up out of the slipstream and use my chest to catch air and help slow the bike as I got on the brakes.  I sat up and nearly got blown off the back of the bike.  My butt came up out of the saddle and onto the pillion and only my fingertips on the grips.  I think my posterior puckering is what actually kept me on the seat and the bike...

So I decided, like you, to gear down, since I wanted more lower end ooomph.  I added 2 teeth to rear sprocket.  Went out the next weekend and coming out from the turn lane under the freeway overpass as I turned left, I straighted up and dropped the hammer in second.  The instrument cluster jumped up and hit me in the face soooo fast I didn't have time to react.  Panicked and took my feet off the pegs to prepare for dumping it and let off the throttle which slammed the front end back down hard.  Feet off the pegs, dropping back to earth from a vertical position, it drove my berries right into the fuel tank, where I slumped over the tank and bars and slowly coasted over to the side of the road to try to crawl off the bike and catch my breath.....

My buddy behind me almost wrecked because he was laughing so hard....

So long DOT short, be careful when you first open it up.  It might surprise you.  I know its not 180hp like mine was, but the effect of that gear my surprise you....
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 02, 2015, 01:40:06 AM
Nice mod Don. I had a chain do just that on an old Elsinor. My dad new someone who could tig so it got patched up.

TN, the front is easier and way less costly than the rear. You get more bang for the buck, but the rear change can fine tune the change.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2015, 10:21:33 AM
TN, the front is easier and way less costly than the rear. You get more bang for the buck, but the rear change can fine tune the change.
Exactly!

My plan for tuning this is to ride and evaluate for now. In my opinion at crawl speeds the motor was nearly stalling so it needed more RPM for the technical dirt stuff. one tooth reduction is a solid change. I might take a tiny of that out with a rear sprocket change, but before that I want to decide on whether to go to the 790 big bore, stay stock 650 or stock bore high compression and cam. Once I decide on that, I'll have a better idea where gearing needs to be for this steam engine bike
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2015, 10:23:07 AM
Oh, and RN...Glad you survived those "Foolish years" so you could still be hanging around.

Saved then? Think God had your back on those instances?
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on October 02, 2015, 12:42:27 PM
Barely. My conversion experience was 8/24/2003.  Perhaps He was sending a message.


Sent from my iPhone using Tapatalk
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 02, 2015, 12:50:57 PM
My foolish years were an RM400. Fractured both wrists in the desert one day. 1977

Jumping a big ditch side by side with a buddy. He got the path on landing, I caught the little berm next to it. Bottomed out the front, bent the bars down next to the forks as I didn't let go. Next thing I was in Indio at the ER, the next day to El Toro for surgery. Worse part was when they had to reset the left wrist a week later,,,,,,,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2015, 12:54:48 PM
My foolish years were an RM400. Fractured both wrists in the desert one day. 1977

Jumping a big ditch side by side with a buddy. He got the path on landing, I caught the little berm next to it. Bottomed out the front, bent the bars down next to the forks as I didn't let go. Next thing I was in Indio at the ER, the next day to El Toro for surgery. Worse part was when they had to reset the left wrist a week later,,,,,,,,,,,,,,,,,,
Me...A 175 Bultaco
Tried to jump a ditch. Caught the rear wheel, tore spokes off the rim I hit so hard, bike did flips came down on top of me after I pole-vaulted into a berm

Almost ended it one day on a ZX-10
On river road near Clarksville, TN. Just had the carbs jetted. Starting to come out of a turn in 3rd, hit it hard and lifted the front wheel while all laid over trying to take the corner as fast as I could. Rocky 50 foot drop off into the Cumberland river on the side I was riding the unicycle to.
That was when I switched to Harleys...
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 02, 2015, 01:07:10 PM
I stayed on the bike,coasted to a stop and fell over. My left wrist was next to arm like it slid off. Still looks funny today!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2015, 03:09:41 PM
Man. that hand would make a wicked fist! Hate to take one in the schnooz from that catcher's mit!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 02, 2015, 03:25:32 PM
 ;)
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on October 02, 2015, 03:28:19 PM
Bultaco!  Ha!  We used to say that Bultaco was Spanish for "no brakes".  Fast as snot but no brakes....loved those things
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 02, 2015, 07:10:40 PM
Bultaco!  Ha!  We used to say that Bultaco was Spanish for "no brakes".  Fast as snot but no brakes....loved those things
Mine had brakes!
Engine compression and my boots!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:12:25 PM
Toyed around with the DR today.

It is a bit cramped for my big carcass, so you may have noticed I raised the handlebars an inch. Next I decided to lower the foot pegs 1" to start with.

You can see here they are easily removed but securely fastened to the frame
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:13:37 PM
I found this cool little spacer kit which lowered the pegs 1" and moved them aft 1" as well
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:14:17 PM
Off with the rubber mounted stockers
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:15:34 PM
And on with the spacer using stock bolts. I used an SAE washer to move the pegs outward from the bike centerline another 3/32" on either side
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:16:35 PM
And then reinstalled the factory pegs, retaining the rubber isolation bisket with large bolts and locking nuts
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 17, 2015, 08:18:20 PM
Are they supposed to go backwards? I would say forward or straight down,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:19:08 PM
If they rub the ground, I plan to attach a one bottom plow share to each peg for some environmental conditioning when I'm riding off road!

Next I started messing with cargo configurations. Not as much space on this bike as I had with Square D or C-Max! I want to carry some extra water...but this along with the gas might be a bit too much me thinks...
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 17, 2015, 08:20:23 PM
Are they supposed to go backwards? I would say forward or straight down,,,,,,,,,,
Roger that...Backward

Forward would crowd the gearshift a lot
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 17, 2015, 08:21:24 PM
Not sure if I like the loss in ground clearance. Maybe just shorten the existing mount and weld? It is awful tall.

Do you see the need to adjust the shift and brake pedal?
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 17, 2015, 08:23:15 PM
If they rub the ground, I plan to attach a one bottom plow share to each peg for some environmental conditioning when I'm riding off road!

Leaving a trail, doesn't sound like a sane idea. Unless you ride over a zombie or 2.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 18, 2015, 06:54:51 PM
Took the DR out for a ride today

It was 47F

Result:
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on October 18, 2015, 08:02:27 PM
The Kentucky version of The Stig.....
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on October 18, 2015, 08:18:21 PM
The Kentucky version of The Stig.....

I think its the KY version of DOG (Dead Old Guy)....... ;)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:00:17 PM
I've reconstituted...something we special ops guys can do...can't talk about it ;-)

So back on the DR build, got a few things done to it today between yard work, voting, workout and two other projects.

First up, I found a neat little guard to protect the rear master cylinder. It bolts on over the cylinder and since it is made from steel, should take a beating
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:01:20 PM
The hardware is longer and includes two spacers to position the shield outboard just a tad bit
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:01:59 PM
And just like that, it was installed
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:02:54 PM
These foot pegs are too shinny, and too short for my liking...off to the parts catalogs
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:04:01 PM
The one remaining stock rectangular mirror is about to go bye-bye
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:05:11 PM
With a twist of a bolt and the slight of hand, it was installed
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:06:42 PM
Next up, in an effort to reduce the power budget on the little alternator this bike has, (around 200 watts) I am switching out the light bulbs to LED's
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:08:05 PM
Two screws and that chore was done
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:09:57 PM
Earlier I removed the factory chain roller, as it is simply not needed. I finally got around to plugging the hole with a button head screw
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:12:08 PM
With that huge gas tank, it is nearly impossible to reach under everything to pull the choke out for cold starts. I will be replacing this with a more accessible one
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:14:12 PM
This simple choke cable attached to the engine case making it totally easy to get to it. Not sure if it is going to survive down there. After I fall over a couple times, I'll be better able to evaluate
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:17:26 PM
I am slowly building up the tool kit for the DR
Pro Cycle sold me this little self contained screwdriver. It failed right away. Unlike everything I ever purchased from them, this thing is absolute junk.

A correct screwdriver is essential for this bike. I did not know this, but the cross head screws have a slightly different pitch than SAE or others we are used to. An American screwdriver can easily strip a jap screw!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 03, 2015, 07:19:21 PM
Picked up this "Grunge brush" to clean the chain and lower side nasty parts

It will live in my tool tube

Also scored a digital air press gage and some of those Jap (JIS??) cross tip bits
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on November 03, 2015, 07:45:22 PM
shed some more light on the different cross bit screws.  News to me
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 04, 2015, 09:25:49 AM
shed some more light on the different cross bit screws.  News to me

From Stanley Screwdrivers:

Japanese Cross Point Screwdrivers
•Designed for fasteners in Japanese electronics

If your Phillips screwdrivers do not fit, you probably need JIS (Japanese Industry Standard) screwdrivers. Slightly larger than American counterparts and more blunt in the larger sizes. Available in #00, #0, #1, #2 sizes. An extra long (12”) #2 is provided for those hard to reach screws found in many copy machines
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on November 04, 2015, 12:31:22 PM
L I B, M R Jap screwdrivers.


Sent from my iPhone using Tapatalk
Title: Re: DR-650 Build Thread Part 1
Post by: cudakidd53 on November 04, 2015, 04:11:25 PM
Once again, getting screwed by foreign goods.......literally! >:(
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 15, 2015, 06:08:57 PM
Had the bike out on a ride of about 150 miles with an off road run today. It is likely to be one of the last opportunities to do so without a through de-icing afterward until the spring thaw is over.

Anyway, I have it geared for trail riding and by 65MPH it is getting all done with the speed thing. Now the 14 tooth countershaft was a bit too high for the trail and the 15 tooth is a bit too short for spirited road ridin' so I think I'll adjust one tooth on the main sprocket and start some fine tuning. I want to be careful not to make too much of an adjustment because the other thing I decided today is that I am definitely going to add the 790cc big bore kit this winter.

Anyway I rode all over the farm at speed and the bike flat out handles great. I did dump it once...hitting the rear brake too hard going down hill and turning...Well, it turned all right, turned over. Ah, nothing was hurt and no farm animals were harmed in the filming of this little spill so we'll just CM.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 15, 2015, 06:10:31 PM
Ooops, got some upside downers in there.

Well either turn your screen over or stand on your head!

Enjoy!
Title: Re: DR-650 Build Thread Part 1
Post by: Armalite on November 17, 2015, 11:05:15 AM
Just personally, I would go back with the 15 tooth sprocket.  You still had plenty of torque, but now with the 14, not only have you lost a significant top end, even though it's not a necessity, your mpg will have dropped dramatically...  If you need to get the most mileage out of a tank, especially if stuff hits the fan, those extra miles from a 15 tooth sprocket could make all the difference in reaching the next destination on tires, or on foot... 

Went through this on one of my bikes...  Dropped to a lower tooth front sprocket, torque was nice, but killed my top end.  Went back to factory sprocket, still had more than enough torque, and had my top end back where it needed to be... 

Just a thought.
Title: Re: DR-650 Build Thread Part 1
Post by: cudakidd53 on November 17, 2015, 04:00:54 PM
Ooops, got some upside downers in there.

Well either turn your screen over or stand on your head!

Enjoy!

 I thought you were just trying to illustrate the upside down dump event!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on November 17, 2015, 05:30:54 PM
I want a picture. (of the fall)

I think the 14t gave him low end without lugging the motor. Many bikes today are geared for cruising not riding.
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on November 17, 2015, 07:21:26 PM
So Don how many teeth on the factory rear?  14/15 was a 7% reduction in speed.

If the factory is 42, then a 43 will get you about 2.5% which is about halfway between.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 17, 2015, 08:16:21 PM
I want a picture. (of the fall)

I think the 14t gave him low end without lugging the motor. Many bikes today are geared for cruising not riding.
With the stock carb the 15 T sprocket was not so dirt (Lugging) friendly.

When I switched to the pumper carb, you can ride around at 5 RPM, it runs just fine, so in reality, I could have kept the 15 tooth cog.

When I get up to 790 CC this winter I'll throw the 15 T back on. With 350 cu in lugging away, I won't need no stinkin sprocket!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on November 17, 2015, 08:22:49 PM
I am sure that pumper helped alot, but 790cc is 350ci !!!!!!  ::) I think it is more like 48.2 ci.

But I have seen a 350 in few bikes, not dirt though.

150mi, that pretty good. I did Tehachapi to Mojave a long time ago but that was all washouts and sideroads.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 17, 2015, 09:39:30 PM
Obviously no 350, but it sure pulls like one!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on November 25, 2015, 10:54:35 PM
The brown truck showed up today

Just got in a S&W Motech center stand.

After much thinkin' and working on the bike with the kickstand down, I could see where a center stand would benefit me greatly, so I bit the bullet and ordered one.

Took the bike out today for a spin in 60F temps. Not too bad overall. I am wearing this thick Harley Davidson riding jacket. It has thick stripes of rhinoceros hide and alligator belly sewn along the sleeves and shoulders. I guess they are part of a skid system. Judging from the stiffness of this thing, I should be able to slide to Missouri before it wears through should I fall!
Title: Re: DR-650 Build Thread Part 1
Post by: KeithB on November 25, 2015, 11:09:17 PM
I'm gonna have to stop by some time and check out the new builds in person.
I like seeing the posts but nothing beats seeing first hand.

There both looking good...

Sent from my XT1080 using Tapatalk

Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on November 26, 2015, 08:12:29 AM
I'm gonna have to stop by some time and check out the new builds in person.
I like seeing the posts but nothing beats seeing first hand.

There both looking good...

Sent from my XT1080 using Tapatalk

Make sure you give it a proper break in ride. He already dumped it once..
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:38:22 PM
Well, had a center stand I ordered a month or more ago sitting around and the Red Dog was eyeing the box. Not that she could damage the center stand, but the bag of hardware would be lost in the grass somewhere and once again I'd want to shoot that dog.

So to save her life, I decided to install the center stand today

Before I get started, take a look at what happens to poly tanks that have gas on the inside and paint on the outside:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:39:47 PM
The center stand is a good idea for this bike, making maintenance in the field easier should I need to pull a wheel off. It is made by a super-duper German company, SW Motech
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:40:44 PM
I dropped the pegs already so that modification is going to complicate things somewhat.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:41:19 PM
The parts and hardware were of a very high quality!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:41:49 PM
Got to brush up on my German some!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:43:22 PM
If using the drop peg kit, you will need to switch out the orientation of the bolts, and I added an extra SAE washer on each bolt to space the mount outboard just a bit so I'd have room for the center stand swing to clear the foot peg bolts
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:44:48 PM
It's a handful, as it all sort of goes together at once. Lots of parts wanting to scatter when you hoist this mass up into place and before you catch a couple threads, securing the thing from falling into the sixth dimension
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:45:49 PM
But with a couple quick flashes of the wrench and an unbelievably hard double spring pull, it's on just like that!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 16, 2015, 09:47:52 PM
I'll be pulling that fuel tank back off to remove the paint from it, but I think I'll wait till mid winter when I tear down the top end for the 790cc big bore kit.

Anyway it now rests on the center stand and I couldn't be happier!
Title: Re: DR-650 Build Thread Part 1
Post by: Dawg25385 on December 16, 2015, 09:48:42 PM
Looks good!


Sent from my iPhone using Tapatalk
Title: Re: DR-650 Build Thread Part 1
Post by: Atkinsmatt on December 16, 2015, 09:49:41 PM
Great job.
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 16, 2015, 10:11:39 PM
I like that center stand Don, pretty cool piece. Now as far as that tank, I have been eyeing a couple as I would like extended range. The one I'm looking at is a 4 gal in place of the stock 2. I also think that they make a six but seems a bit overkill as I have that large rear rack I can add more fuel to as well. Other than the paint failing are you happy with this mod?
Title: Re: DR-650 Build Thread Part 1
Post by: JR on December 16, 2015, 11:54:03 PM
Center stands are worth their weight in gold when you need em. Nice looking stand. Plus the additional weight is about as low as you can go!

Funny, my understanding was the paint would adhere is painted before you you put fuel in it. Live an learn. Maybe someone could make a vinyl overlay for that?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 17, 2015, 10:23:09 AM
I like that center stand Don, pretty cool piece. Now as far as that tank, I have been eyeing a couple as I would like extended range. The one I'm looking at is a 4 gal in place of the stock 2. I also think that they make a six but seems a bit overkill as I have that large rear rack I can add more fuel to as well. Other than the paint failing are you happy with this mod?
I'm definitely happy with this mod.

Couple things though. With 40 pounds sitting up high, the bikes handling is different between being full and down to around a gallon.

And considering the incredible fuel mileage, the change takes several weeks (To use all that fuel)

I have learned to just run it at around 4 gallons.

As for the tank coloring, I can do a couple of things.
I could remove the paint and just run it in the natural translucent plastic color
Or, I could purchase another black or gray tank
Or, I could fashion a cover for it from OD or cammo colored material and do a Molle thing where I could attach pouches as I saw fit.
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on December 17, 2015, 10:27:02 AM

As for the tank coloring, I can do a couple of things.

1.  I could purchase another black or gray tank
2.  I could fashion a cover for it from OD or cammo colored material and do a Molle thing where I could attach pouches as I saw fit.

Order a black tank or whatnot, makes the bike ride able. Use the tank that's on there to try out your Molle idea. If it doesn't turn out, then you can still use it as a spare.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 17, 2015, 10:27:56 AM
Center stands are worth their weight in gold when you need em. Nice looking stand. Plus the additional weight is about as low as you can go!

Funny, my understanding was the paint would adhere is painted before you you put fuel in it. Live an learn. Maybe someone could make a vinyl overlay for that?
I am not concerned about adding weight to this bike
First of all
Since Blaine talked about the Kettle ball exercises, I have been wearing out a 50 pounder.
So
Don is losing weight faster than I am adding it to the bike!
And
All Don's weight is up high where it matters!
Secondly
I reckon this modified bike to be around 40-42 HP now. It made 36-37 stock. The pipe, carb and airbox mod pushed it up. But the 790 big bore kit with the stage 2 cam will push that figure into the mid 50 range. So we can carry a wee bit more weight if it serves a useful purpose.

1000 more kettle ball swings and I'll be able to carry a surefire 60 rounder all topped off!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 17, 2015, 10:28:45 AM

As for the tank coloring, I can do a couple of things.

1.  I could purchase another black or gray tank
2.  I could fashion a cover for it from OD or cammo colored material and do a Molle thing where I could attach pouches as I saw fit.

Order a black tank or whatnot, makes the bike ride able. Use the tank that's on there to try out your Molle idea. If it doesn't turn out, then you can still use it as a spare.
Yea, I like the Molle idea.
Don't think anyone has done that yet
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on December 17, 2015, 10:32:42 AM
Yea, I like the Molle idea.
Don't think anyone has done that yet

Only thing I can think of is the pouches MIGHT interfere with the bars when you go to turn and you really crank on it, depending on the pouches. Just a thought.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 17, 2015, 10:34:43 AM
Yea, I like the Molle idea.
Don't think anyone has done that yet

Only thing I can think of is the pouches MIGHT interfere with the bars when you go to turn and you really crank on it, depending on the pouches. Just a thought.
Keep em down low
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 17, 2015, 11:11:07 AM
Found a pic of that big bore engine mod:
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 17, 2015, 12:02:07 PM
Don, you kinda confirmed my suspicions that 4 gal is a large enough tank up front.......
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 17, 2015, 12:12:34 PM
Don, you kinda confirmed my suspicions that 4 gal is a large enough tank up front.......
I mean I could see where 4-5 could work.
I went mugo because I intended to run a whole "Mission" without refueling.
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on December 17, 2015, 12:23:21 PM
Keep em down low

Might get knee to pouch contact dependent on pouch.  Or brush grabbage on the pouch. Just thinking of things that will make your "mission" ride have a painful moment or 2. Wait a minute vines WILL grab anything and everything they can, especially when it's dark.
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 17, 2015, 12:28:21 PM
Don, you kinda confirmed my suspicions that 4 gal is a large enough tank up front.......
I mean I could see where 4-5 could work.
I went mugo because I intended to run a whole "Mission" without refueling.

Copy
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 12:42:39 PM
Met a great guy just now. Mike who owns a company that started making Molle tank covers for bikes.
I was going to build my own, but this guy has this down to a science, just take a look:

http://tankvest.3dcartstores.com/Gallery_ep_41.html
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 12:52:20 PM
Here is what these bags look like with some various storage pouches fitted
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 12:52:54 PM
Boy if that ain't the ticket.....

This will hold my scanner perfectly ;)
(http://tankvest.3dcartstores.com/assets/images/tv/klr650ims/tvp5.jpg)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 12:58:30 PM
Boy if that ain't the ticket.....

This will hold my scanner perfectly ;)
http://tankvest.3dcartstores.com/assets/images/tv/klr650ims/tvp5.jpg

Shawn,

Mike should be showing up in the intro section.
He hasn't done a DR650 with the Acerbis tank, I think, but he has a way.
I'll let him clarify, but he can get the tank dimensions then build a cover.

That would open the door to other models as well.

Anyway, we'll get to see it first hand getting developed for the DR
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 01:01:57 PM
Also... Was thinking

This project is needing a name

I've had a few thoughts about a name for this bike

"Scout" comes to mind, as in Army scout
Another is "Steamer" because of the ancient steam powered engine
Of course, we are already using just "DR" so that's a possibility
Hmmm...
Title: Re: DR-650 Build Thread Part 1
Post by: rasimmo on December 18, 2015, 01:09:34 PM
I like the tank wrap. It seems you can get a Molle wrap for just about anything. Orca coolers even makes one for some of their ice chests.
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on December 18, 2015, 01:35:20 PM
Man that's sweet. Might have to start a bike project now just so I can get one of those. That thing should add a good amount of storage to a vehicle that has very little to start with!
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 02:33:23 PM
Shawn,

Mike should be showing up in the intro section.
He hasn't done a DR650 with the Acerbis tank, I think, but he has a way.
I'll let him clarify, but he can get the tank dimensions then build a cover.

That would open the door to other models as well.

Anyway, we'll get to see it first hand getting developed for the DR

I could possibly ship him the new 4 gal tank if he hasn't done one for wr450f.....
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 03:07:29 PM
Shawn,

Mike should be showing up in the intro section.
He hasn't done a DR650 with the Acerbis tank, I think, but he has a way.
I'll let him clarify, but he can get the tank dimensions then build a cover.

That would open the door to other models as well.

Anyway, we'll get to see it first hand getting developed for the DR

I could possibly ship him the new 4 gal tank if he hasn't done one for wr450f.....
When Mike shows up down here on this thread, ask him about it

There's a lot more coming

We have already talked about a Molle panel for the doors of Square D and the seat backs of C-Max.
I can see just some plain old panels of various rectangular shapes and sizes one could buy, then affix anywhere, like the inside of a topper or on a wall of a camper.

My brain (Small as it is) is werkin here...

Mike where are you?
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 04:16:13 PM
Also... Was thinking

This project is needing a name

I've had a few thoughts about a name for this bike

"Scout" comes to mind, as in Army scout
Another is "Steamer" because of the ancient steam powered engine
Of course, we are already using just "DR" so that's a possibility
Hmmm...

Scout is already being used on another bike thread......... ::) sorry  ;D
Title: Re: DR-650 Build Thread Part 1
Post by: Michael at EFI on December 18, 2015, 04:41:40 PM
Hey guys, thanks for the warm welcome and I'm glad to see the Tank Vest getting a warm reception as well. 

We can make the Tank Vest for just about any motorcycle out there.  Here's the catch.  We need a motorcycle to pattern for each model and gas tank.  The patterning takes about 2 weeks to do.   

The Tank Vest is 100% made in the USA. 

Any MOLLE pouches will work with the Tank Vest. 

We're currently working on many special application pouches and accessories for the Tank Vest such as a secure carbine mount, administrator pouch, QD medical pouch, and more.   

Please feel free to ask any questions you may have.  I'll do my best to answer them. 

Michael
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on December 18, 2015, 04:57:11 PM
Don,  Since "Scout" is already used....

"Donor Sled" is available?  That's what my Dr. buddies call them...all the good organs come from motorcycle riders....
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 04:57:38 PM
Looking at a Clark 4 gal tank for the 2015 WR450F, have you done this tank before? If not can I drop ship to you?
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on December 18, 2015, 04:58:18 PM
Personalized plate:  DNRSLD
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 05:03:15 PM
Don,  Since "Scout" is already used....

"Donor Sled" is available?  That's what my Dr. buddies call them...all the good organs come from motorcycle riders....


I second this, kinda a dual purpose name if you will. Donor meaning I can "borrow" it to play with when I visit the farm..... ;)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 06:57:36 PM
Don,  Since "Scout" is already used....

"Donor Sled" is available?  That's what my Dr. buddies call them...all the good organs come from motorcycle riders....
Mine would be well used, albeit well cared for!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on December 18, 2015, 06:58:31 PM
Don,  Since "Scout" is already used....

"Donor Sled" is available?  That's what my Dr. buddies call them...all the good organs come from motorcycle riders....


I second this, kinda a dual purpose name if you will. Donor meaning I can "borrow" it to play with when I visit the farm..... ;)
Yea you can borrow it
Title: Re: DR-650 Build Thread Part 1
Post by: Michael at EFI on December 18, 2015, 07:14:55 PM
Looking at a Clark 4 gal tank for the 2015 WR450F, have you done this tank before? If not can I drop ship to you?

We haven't but we can probably make it happen.  Let me see if there is one locally if not, I'll take you up on that offer.

Michael
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 08:13:24 PM
Planning on buying it first week or so of Jan so you have some time.... Thanks
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on December 18, 2015, 08:14:56 PM
Mine would be well used, albeit well cared for!

The bike or you? ???
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on February 11, 2016, 09:23:48 PM
Adding to the travelling tool kit of the DR

Added tire irons, spare tubes, tire patches, Rim guards for changing tires, a bead buddy to help reinstall a tire, some balance beads, a valve core tool. An inner tube puller, and some other niceties to have along
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on February 11, 2016, 09:26:20 PM
The tire beads feed into the tube via the plastic bottle. Pour in two packs and you never need to add balance weights which sling off, just like on trucks

The vale cores have a filter that prevents the beads from clogging the tiny passages
Title: Re: DR-650 Build Thread Part 1
Post by: JR on February 12, 2016, 12:09:36 AM
Now thats a good kit.
Title: Re: DR-650 Build Thread Part 1
Post by: cudakidd53 on February 12, 2016, 07:15:49 AM
Quite a size difference between rear and front tubes!  What type of air pump are you thinking?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on February 12, 2016, 09:03:53 AM
Quite a size difference between rear and front tubes!  What type of air pump are you thinking?
I'd like to carry those CO2 inflators but maybe just a good hand pump, bicycle size would be best.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on March 19, 2016, 03:50:16 PM
The DR-650 was nearing being a total loss! Really!
Had all sorts of winter dust on it!

I was scared...I mean little school girl scared! But I hit it with the pressure washer and just like that it was fully restored!

Amazing!

Restored the tiger partially as well. Got tired of water blasting skin off my face so I only did some of it
Title: Re: DR-650 Build Thread Part 1
Post by: JR on March 20, 2016, 04:28:24 AM
The DR still looks good, but I have expect the tiger to hover.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:45:06 AM
So we installed a new rear tire today. We meaning me and one of the pre-Rangers.

It's good stuff doing hard work with your son!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:45:43 AM
He successfully yanked out the rear axle
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:46:16 AM
And pulled out the rear wheel/tire

I'll be replacing it with a Shinko 805 Cross Fly which is a 40% highway/60% off road tire. The Shinko is a 130-17 whereas the stock Bridgestone is a 110-17, so I'll be getting a bit more cross-section.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:47:32 AM
We used a vise to break the beads off the lip, which was a bit of a chore since the tire had been on there since 2012
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:48:46 AM
Then, using the new tire iron/spoons the first bead is pried off the wheel lip
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:49:49 AM
Then the inner tube can be fished out

This one will become a spare
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:51:00 AM
Then the PR moved in and pulled the tire off the wheel by doing the prying thing and scratching up the wheel all to heck and back!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:52:35 AM
The inside of the wheel looked great so with some lubing of the new tire bead, we worked it back onto the wheel
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:53:26 AM
Inner tube next, using the valve stem fishing tool
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 09:54:28 AM
Then just like that, the tire was on and reinstalled on the bike...Mission Complete minus the test flight!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on May 10, 2016, 10:31:49 AM
Good looking tire. I do like the angled lugs on the first tire for cleaning though.

Does it run?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 10:41:50 AM
Good looking tire. I do like the angled lugs on the first tire for cleaning though.

Does it run?
Yes it runs!

Drove it around after the tire swap. Just like normal. Throttle it and it lofts the front tire just like always
Title: Re: DR-650 Build Thread Part 1
Post by: Wilbur on May 10, 2016, 01:42:27 PM
Looks good Don. And good work by the PR.....I cant see any scratches from here.  ;)
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on May 10, 2016, 04:09:05 PM
Easy Big D........ With sq d there he musta assumed this was the non running vehicle parking area...... ???
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 04:24:22 PM
Looks good Don. And good work by the PR.....I cant see any scratches from here.  ;)
Doesn't matter

Scratches lead to scars

and scars are cool!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on May 10, 2016, 06:49:30 PM
But SD does run, just doesn't move,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on May 10, 2016, 07:35:02 PM
Yeah guess I did read that he got it running.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 07:56:54 PM
But SD does run, just doesn't move,,,,,,,,,,,,
Yep, it does

Currently chasing down a pesky transmission oil leak...
Title: Re: DR-650 Build Thread Part 1
Post by: JR on May 10, 2016, 08:10:35 PM
No pics??
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 10, 2016, 08:52:32 PM
No pics??
Nope, sorry
Title: Re: DR-650 Build Thread Part 1
Post by: JR on May 10, 2016, 11:24:24 PM
Had to try, but she is running!!!!
Title: Re: DR-650 Build Thread Part 1
Post by: turn_one on May 11, 2016, 03:46:20 PM
I gotta say, I'm impressed.  Was this your first tire change??  Most people, including myself can struggle with this for hours...then give up and take it to a bike shop.  Maybe because you lost a tooth in the process or you're tired of loosing paint from your wheel.

Nice work.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on May 11, 2016, 03:47:31 PM
I gotta say, I'm impressed.  Was this your first tire change??  Most people, including myself can struggle with this for hours...then give up and take it to a bike shop.  Maybe because you lost a tooth in the process or you're tired of loosing paint from your wheel.

Nice work.
Well, first in a long time...Like decades

Had help...Your brother!

How's the tooth? ;-)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 07, 2016, 09:17:07 PM
I couldn't with the paint blistering on the fuel tank any longer, so I power washed it!

Not sure what I am going to do with it from here. Mike never came through with the tank bag so I just might take a stab at it myself. For now it will remain ugly
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 07, 2016, 09:18:59 PM
I removed the factory tool kit holder and installed a 3" tool tube some time ago. But after rolling up the tool kit, there is not enough room for it, so I'm upgrading to a 4" tube
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 07, 2016, 09:21:14 PM
Bit of a difference in tool tubes on this machine!

I stuffed the spare 21" front 4mm HD inner-tube into the front fender bag. Had to squeeze, but it made it in there!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 07, 2016, 09:23:31 PM
I stuffed all the tools into a tool bag that was laying around. It looks like a good fit for the 4" tube
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on June 07, 2016, 09:52:12 PM
Mike never came through with the tank bag so I just might take a stab at it myself. For now it will remain ugly

Was wondering about him last weekend....
Title: Re: DR-650 Build Thread Part 1
Post by: JR on June 07, 2016, 11:15:17 PM
Jusr mod a nice molle bag for it.
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on June 08, 2016, 07:34:22 AM
What would be cool is if you could create some mounted clips on the tank and some added clips to a backpack so you could dual purpose a backpack to clip onto the tank and remove and wear when you get off. As handy as you are you could sew some short straps and clips to a nice pack and tuck the shoulder straps under it when you clip it on the tank.


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Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on June 08, 2016, 10:07:17 AM
What would be cool is if you could create some mounted clips on the tank and some added clips to a backpack so you could dual purpose a backpack to clip onto the tank and remove and wear when you get off. As handy as you are you could sew some short straps and clips to a nice pack and tuck the shoulder straps under it when you clip it on the tank.


Sent from my iPad using Tapatalk

Extra MOLLE ruck or ALICE adjusting straps with fastex fasteners on one end. Most assault pack or backpacks have fastex buckles on them. If not a loop of 550 can and will hold a fastex to a ruck.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 09, 2016, 11:08:22 AM
Jusr mod a nice molle bag for it.
I think so
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 09, 2016, 11:08:53 AM
What would be cool is if you could create some mounted clips on the tank and some added clips to a backpack so you could dual purpose a backpack to clip onto the tank and remove and wear when you get off. As handy as you are you could sew some short straps and clips to a nice pack and tuck the shoulder straps under it when you clip it on the tank.


Sent from my iPad using Tapatalk
Great idea!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on June 09, 2016, 01:36:07 PM
With those big wings on the tank keeping something on there should be easy. With the upper area, tuff to fit though. But I have faith in BD.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on June 09, 2016, 05:18:22 PM
With those big wings on the tank keeping something on there should be easy. With the upper area, tuff to fit though. But I have faith in BD.
Just gave it a good shakedown run. I think the tires are out of round and half filled with concrete. I was shakin all over the place riding the new 40/60 tires on the strasse. Runs well other than that though
Title: Re: DR-650 Build Thread Part 1
Post by: JR on June 09, 2016, 06:12:33 PM
Maybe your spoiled with the Tiger?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on July 22, 2016, 10:22:28 PM
I was messing around with the DR a bit today. It backfired and then refused to run properly. It is acting like it has a vacuum leak. I don't know this 40mm Mikuni that well, so I guess I'll have to become an expert on yet something new.

I drained the gas to be sure it wasn't bad gas or something simple like that. While I have it down, I'll run a dual gas line setup into a larger filter so that I can capture fuel from either side and any time
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on July 22, 2016, 10:40:42 PM
It backfired and then refused to run properly.

She's cranky since you haven't been paying any attention to her.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on July 22, 2016, 10:50:22 PM
It backfired and then refused to run properly.

She's cranky since you haven't been paying any attention to her.
Probably
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:20:52 AM
So, I have been messing with this bike, trying to correct the problem.

It is backfiring, or more like "Coughing" back through the carb when it idles.

It will only idle with the choke on, but will run with the choke off, although only after "Bliping" the throttle. This Mikuni has an accelerator pump so the added bit of fuel is making that happen.

So the general rule is if it backfires through the exhaust, it's too rich. If it coughs back through the carb, it is too lean.

So what caused a good running engine to suddenly start to run lean???

Anyway I started by stripping it back down
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:22:40 AM
One of the two plugs was really sooty and appeared to not be sparkin' and the other was black, and all that due to running with the choke on, I would suspect.

So I replaced them with a new set of NGKs
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:26:52 AM
I fussed with this thing all afternoon, and by night fall, wasn't any further along that I was when I began.

Now keep in mind, the thing was jetted from ProCycle for the header and air box mod and was running strong just before the backfire, so it's not jet size or metering rod and probably not accelerator pump related. It's more like something broke, it developed a vacuum leak, or some internal diaphragm ruptured.

Anyway, I threw in the towel and did a couple other things.

First up, I mounted that 4" ID tool storage tube in place of the 3" one that was on there up to this point
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:28:09 AM
Knowing that I will be stuffing things way down deep inside, I placed a "Yank" strap in the tube first so that I would be able to pull the deep contents out
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:29:23 AM
Because The first thing going into that cavernous hole is a spare tube for the back tire
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:30:27 AM
Followed by the tool kit, which is changing weekly as I add to or replace things
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:32:00 AM
It fit in there just about right...But I wish I had made it just 1" deeper...Guess I'll make another one!

The yank strap secures onto Velcro top and bottom
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:33:52 AM
Not wanting to stop there. I tried to cram the spark plug, rubber patches, and the spare bolt box in there, but the bolt box wouldn't fit!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:34:33 AM
But everything else did!
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on August 03, 2016, 09:46:21 AM
Not wanting to stop there. I tried to cram the spark plug, rubber patches, and the spare bolt box in there, but the bolt box wouldn't fit!

Ziploc bag, if worried about bag tearing open; lay bag flat on table (before putting bolts inside) apply 100MPH tape to outsides of bag on both sides. Watch your worries disappear, much like the bolt bag inside the tool tube.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:46:43 AM
Finally, I added a quick connection for a trickle charger which will be hooked to a solar cell
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 09:47:24 AM
Not wanting to stop there. I tried to cram the spark plug, rubber patches, and the spare bolt box in there, but the bolt box wouldn't fit!

Ziploc bag, if worried about bag tearing open; lay bag flat on table (before putting bolts inside) apply 100MPH tape to outsides of bag on both sides. Watch your worries disappear, much like the bolt bag inside the tool tube.
That's a good idea young man!
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 03, 2016, 10:12:01 AM
Maybe the gas was just old enough to mess with something..
Could be the intake valve(s) are a little tight.....gummy tight or adjustment tight. I'd take 5 minutes and run the valves. I think you're supposed to do that after break in anyway.
Title: Re: DR-650 Build Thread Part 1
Post by: moto123 on August 03, 2016, 10:45:26 AM
The accelerator pump is basically a rubber diaphragm.  I have had similar idling issues when it dried up and cracked.  I chased jetting for days until finding that the crack in the rubber pump.  Might be worth a look.  Either that or your idle circuit got plugged with dirt.
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 03, 2016, 11:14:55 AM
I was thinking old gas too, something gummed up.

If you need a little more room, do you really need a dedicated chain cleaner brush in there? Maybe a good brush for many uses and a small can of spray cleaner?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 01:15:58 PM
Maybe the gas was just old enough to mess with something..
Could be the intake valve(s) are a little tight.....gummy tight or adjustment tight. I'd take 5 minutes and run the valves. I think you're supposed to do that after break in anyway.
Its been serviced once, but going after valve adjustment might be something I'll look into. But again this happened all at once...Although it did have some older gas in the tank
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 03, 2016, 01:59:36 PM
If a rocker is loose, then you'll know if it has a sticky valve. Maybe throw some seafoam in the tank and let it idle for a few? I use the heck out of that stuff out here where gas will varnish in 3 months of heat..
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 03, 2016, 02:20:37 PM
I love seafoam,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on August 03, 2016, 02:34:18 PM
Finally, I added a quick connection for a trickle charger which will be hooked to a solar cell

I need to do this for the WR450..........
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 03, 2016, 10:04:38 PM
While over at the two wheel dealership, I was checking out the new Kawasaki KLR-650 in the blown up digi-camo pattern. Thing has a good look, but no power, a bad front suspension, a poor rear suspension and is loved by nearly as many who ride the steam powered DR-650 like mine
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 04, 2016, 12:33:28 AM
Looks like a 007 bike with all stuff hanging in the back. I do like the camo if they would address the power.
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 04, 2016, 12:38:22 AM
Don, the guy who helped me with my powder coating is an off road adventure biker.  1100 cc KTM.
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 04, 2016, 12:39:00 AM
(http://uploads.tapatalk-cdn.com/20160804/4b29a738cdc092febd47aec1da110c80.jpg)



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Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 04, 2016, 12:42:24 AM
Don, your gel seat is calling you,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 04, 2016, 09:14:26 AM
Looks like a 007 bike with all stuff hanging in the back. I do like the camo if they would address the power.
That engine is essentially unchanged from 1987, so I doubt we will ever see any big engineering changes. It's like the DR650. Just an old tug boat that has achieved small block Chevy popularity and a huge aftermarket
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 04, 2016, 09:15:23 AM
(http://uploads.tapatalk-cdn.com/20160804/4b29a738cdc092febd47aec1da110c80.jpg)



Sent from my iPhone using Tapatalk
500 miles a day is tough

1500: Insane
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 04, 2016, 09:34:46 AM
I just did the math on that. 62mph for 24 hours. Seems tough to imagine


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Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on August 04, 2016, 09:51:06 AM
While over at the two wheel dealership, I was checking out the new Kawasaki KLR-650 in the blown up digi-camo pattern. Thing has a good look, but no power, a bad front suspension, a poor rear suspension and is loved by nearly as many who ride the steam powered DR-650 like mine

Minus the camo job, it's not a bad looking bike.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 04, 2016, 10:22:37 AM
While over at the two wheel dealership, I was checking out the new Kawasaki KLR-650 in the blown up digi-camo pattern. Thing has a good look, but no power, a bad front suspension, a poor rear suspension and is loved by nearly as many who ride the steam powered DR-650 like mine


I like the camo scheme, but it comes in either black or Kawa green depending on the year. I'd say Black is the most common color for it.

The thing that makes that bike interesting is that it is water cooled. Water cooled engines can make about 50% more power than air cooled siblings. Example is the Water cooled Suzuki DRZ-400 vs my Air Cooled DR-650. The 400 cc bike, although being 250cc smaller, is a bunch more powerful than the bigger DR.

But, sadly, with the Kawasaki, the engineers decided not to put any power into their bike. It is a sled. Add to that it is way heavy. It approaches the weight of my big Triumph Tiger 800 with its water cooled three cyl engine.

So the combination of heavy and under-powered is not great in my view. That's why I went with the DR-650 with it's lightweight, air cooled simplicity

Minus the camo job, it's not a bad looking bike.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 04, 2016, 06:47:15 PM
I still don't have this thing fixed!

Cleaned it with sea foam and other sprays today and it still kicks back through the carb and backfires loudly on decel from revving it!

GRRRRRRRRRRR!!!!!
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 04, 2016, 07:44:31 PM
Did you check the valves? Wait, let me answer. NO you didn't!
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on August 04, 2016, 07:51:33 PM
Rofl, H lover just handed the pilot his rear......
Title: Re: DR-650 Build Thread Part 1
Post by: cudakidd53 on August 04, 2016, 07:55:51 PM
What about accelerator pump (diaphragm) tear like someone mentioned previously?
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 04, 2016, 08:14:22 PM
I think it's the pilot jet clogged by bad gas

Watched a vid of a bike doing the same exact thing

Or a vacuum leak that just started up
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 04, 2016, 09:18:30 PM
oooh oooh oooh, let me Don, let me!

Ken....your fired....
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 04, 2016, 11:12:23 PM
 :)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 07:57:16 PM
I am really be-fuzzled by this thing.

I did a lot of other stuff today, but I wanted to get this bike buttoned up and out of the way. I really wanted to get some things done on SquareD

So I checked the jetting, well some of the jetting, inspected for and I think I found some vacuum leaks (More than one) but very small ones. Apparently the rubber collar which clamps onto the carb barrel is notorious for leaking. Spraying carb cleaner around the flange produced a momentary increase in "Idle/stumble" speed.

So I addressed all that and the darned thing is still doing the exact same thing!

My carb has a nice access plug in the fuel bowl which one can pull to gain access to the pilot jet.

It's here:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 07:58:15 PM
Now, remember this carb is not all that old but look at this weird looking green stuff coating the inside surface:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:01:11 PM
Yea...And that with the fuel filter that was installed!

Once removed, you have access to the main pilot jet and the metering valve barrel, which I removed and disassembled. It also had that strange green film all over it.

It did not clean up easily, like it was anodized on there or something. And I also had sea foam soaking in that fuel bowl for 24 hours
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:02:54 PM
I sprayed a bunch of carb cleaner up inside that hole and then removed the air metering valve and cleaned it and sprayed out the passages
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:04:03 PM
Then the idle fuel metering screw
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:05:04 PM
Next, I installed premium Parker hose and another new fuel filter
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:07:43 PM
Thinking I was done with the carb problem, while I had the tank off, I wanted to place some more padding into the areas under the fuel tank. I can see it moving about a little while riding aggressively. These two rubber discs hold the front of the tank, while two bolts secure it in the rear. I'll be doing something about this
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:09:40 PM
So, using foam stripping designed to fit between the truck bed and a topper, I built up several areas
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:34:14 PM
...And, as expected, the tank was very snug, with zero FAS (Flop About Syndrome) ;)
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:40:26 PM
And this is the point where I filled the carb and fired it up expecting all to be good in my steam engine, but it was not to be.

Ba-wosh it said and the engine stalled, and I knew right away that I had a bunch of well sealed clean parts acting in exactly the same manner as before.

This has me scratching my head and wondering if some ignition module suffered a partial failure or someone cast a spell on it or something!

But, I went on to remove the unnecessary kick stand safety switch. For a fast getaway bike, wait-a-minute switches are not desirable. So I made it go away.

Here's the little sucker:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:43:06 PM
I wired around it and removed the unnecessary parts
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:44:24 PM
It's all cleaned up, and I even gained a hard point which I just may use for something down the road
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 05, 2016, 08:44:59 PM
So, here I sit, still not finished!!!!!!!!!
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on August 05, 2016, 10:30:59 PM
Just want to point out the obvious. The sea is green & you were using "sea" foam...... ???
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 05, 2016, 10:37:21 PM
I do wonder what the green is. Whats in your gas?
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on August 05, 2016, 10:48:59 PM
To me it looks like sea foamed varnish.

Chief, how old was the gas? Regular or premium?
I ask due to the ethanol fiasco, and the havoc it causes with rubber bits.

It looks to me like varnish build up, which with today's gas happens fast.
The green from the sea foam.

Now what is causing the backfiring and not running well, still rests inside that carb I think.
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 06, 2016, 08:28:52 AM
Agreed^^
Carb and/or valves. Probably need to dip the carb and jets to get all of it. ...regular carb cleaner usually isn't strong enough. Seafoam  works on thin layers but can take days to get rid of buildup

Sent from my SM-G900V using Tapatalk

Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 08:55:35 AM
Got this response from a query I placed over at: DRRiders, a great site to support DR-650 riders.

Makes sense, here it is:

MISSION NOT-IMPOSSIBLE:
the green is from your fuel....yep, no aliens died in there  :OMG: ......it's just the fuel
yes, you rode it through the winter, but apparently, the fuel that was in your tank sat just long enough to start to breakdown and start to clog up the joint.......and that is what is causing your problems

never mind that it worked great one ride, and the next it didn't, the backfire did not cause the problems, but it was the gummed up carb that caused the backfire, and the motorbike not running right....these are all classical conditions of a gummy carb with a still gummed up pilot-jet....CLASSIC!

yes, you did spray out your carb and do some SeaFoam soak, but that is not enough
you also need to remove the jets....ESPECIALLY THE PILOT JET....soak those jets in cleaner overnight,
then the next day, spray compressed air through every single jet and each orifice too before putting it all back together
I actually spray every jet and every hole, slide, bump, and orifice numerous times.....and I use a whole can of Gumout doing it. And only then do I go for the COMPRESSED AIR.

and sometimes, even compressed air through that pilot jet just is not enough, and buying a NEW ONE is the best answer
that pilot jet has a very small hole, and sometimes they just do not get completely clean....hey, they are cheap, so why not make absolutely certain it is completely clean before putting it all back together. Five bucks for a new jet is a lot easier than the entire time it takes to take it all apart again..... :old:

there's your modified mission, go ahead and complete it as directed and you should find your motorbike is now running in tip-top shape once again.....oh yeah, make certain that you drain out every drop of that older fuel and fill the bike with brand-new-fresh-from-the-pump-stuff when you have it all back together again

IMPORTANT SAFETY TIP: YOU MUST do a proper and complete carb clean removing those jets & blowing them out WITH THE COMPRESSED AIR.......anything short of following all of this (cheating even in the slightest) and you may find you only wasted your time

GOOD LUCK on your mission (should you decide to accept it)


Sometimes a loud pop (backfire) can be SO INTENSE that it may cause internal damage....SOMETIMES, but in this case, the first thing is to do is the complete carb clean, put in completely fresh fuel, clean the air filter, and go for a ride. If after that it still is not running right, only then is the time to start looking inside.

Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on August 06, 2016, 11:08:43 AM
I'm curious as to what you wrote to get such an awesome response.
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on August 06, 2016, 11:17:33 AM
'Pilot' jet...

Sorry boss, couldn't resist.
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 06, 2016, 12:26:16 PM
Get some of this boss. I promise you that it is the only way to go. ...smaller version of what shops use.....very efficient. ...will melt plastic .(Also works well at removing paint on small projects )
Take carb completely apart, soak all metal pieces for 4-6 hours , rinse with water, blow out thoroughly,  reassemble.

Sent from my SM-G900V using Tapatalk

Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 06, 2016, 12:26:36 PM
(http://uploads.tapatalk-cdn.com/20160806/549f3ad4c547c874940e75750e13c383.jpg)

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Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 06, 2016, 01:18:20 PM
Ken, I used to see a air powered cleaner that worked in a 5 gallon drum. Looked for one but have had no luck, do you know the correct name or where to get one?
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on August 06, 2016, 03:35:32 PM
I haven't seen one of those since HS....an agitator maybe? I actually made one from an old ice cream maker, turned on it's side, that drops a slim bar down through the lid. We do probably 20 carbs a year and I must say, it works pretty good!
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 06, 2016, 03:49:29 PM
I was looking for one of those when I got the sonic cleaner. Seemed like a good alternative but one of those would be great.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 10:54:52 PM
Fixed it!

It was the pilot jet which was clogged completely shut!

I removed everything first
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 10:55:44 PM
Next I pulled the bottom and then the top off
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 10:58:29 PM
And pulled out the jets.

This little fella, a size 22.5 was completely clogged shut!

I sprayed it for awhile with carb cleaner but couldn't break the blockage. So I probed the holes with a single brush bristle and poked through the blockage. Some more spraying and I had a hole again...A very small one
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 11:00:03 PM
Reassembling a carb into two rubber sleeves is not an easy task. It took some time to wiggle it into the proper position, but in the end after sacrificing enough good quality epidermis, I won the day!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 11:03:10 PM
The test run was just fine. I set both the air and the fuel screws exactly 2 turns out. I'm writing this here not because you give a flying hoot, but because I will undoubtedly come back to this post as a reference as to what I actually just did!

So with no time to spare, I started another project...Wrapping that tool tube with some camo vinyl I still had. Thought I ought to use it before the dog chewed it all up!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 11:06:36 PM
Well, that worked out OK, so I decided to wrap the muffla' as well

Now, I know what you're thinkin'

Did he fire five times, or six?

Sorry, different movie. Will that stuff melt off and make a mess. That's it, right?

Well, there has been a decal on there since new and it hasn't so much as gotten loose. All that fiberglass insulation inside, seems to do just that. Keep the heat on the inside. I've touched that can a lot over the years, and it never gets that hot, so where we go:
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 11:08:56 PM
That finished it and me. Starving to death and with an angry wife and two kids thinking about disowning me, I didn't really have the time to reassemble the bike, but I wanted to be done with it, so I did!

But with that big 4" tool tube, I had to create an extension for the left side cover
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 06, 2016, 11:10:14 PM
And that was that with the addition of the rest of the almost dog-chewed and nearly missing balance of parts
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 07, 2016, 08:46:32 AM
Looks good now go ride!


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Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 07, 2016, 01:54:26 PM
Looks good now go ride!


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I took the Triumph to church today...didn't want the DR to hiccup and not make it there

I'll ride it tonight
Title: Re: DR-650 Build Thread Part 1
Post by: BobbyB on August 07, 2016, 03:06:17 PM

didn't want the DR to hiccup and not make it there

I'll ride it tonight

I think this is how really low budget horror films start..


Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 07, 2016, 08:46:06 PM
I rode it, and it didn't leave me stranded!

Ha!
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 07, 2016, 09:19:35 PM
and that my friend is minimum acceptable threshold.
Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 08, 2016, 12:48:58 AM
Guess that means no more Gasohol or lots of stabilizer! Looks at the marine stabilizer, supposed to be better on that junk.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 09, 2016, 02:13:46 PM
Guess that means no more Gasohol or lots of stabilizer! Looks at the marine stabilizer, supposed to be better on that junk.
OK!
Title: Re: DR-650 Build Thread Part 1
Post by: rpar86 on August 09, 2016, 04:48:22 PM
My Honda mower has been through two carbs in the last 6 years with the latest being this past April. 4 months later it is already surging at idle and sounds as bad as it did before, and I only run 92 octane ethanol-free fuel in it :(  Carbs are a pain, glad you figured yours out!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 09, 2016, 10:44:15 PM
My Honda mower has been through two carbs in the last 6 years with the latest being this past April. 4 months later it is already surging at idle and sounds as bad as it did before, and I only run 92 octane ethanol-free fuel in it :(  Carbs are a pain, glad you figured yours out!
Well, now its leaking!
Yep, puddle of benzene on the garage floor and the dog refuses to lick it up!
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on October 12, 2016, 11:26:22 PM
Get this fixed or is it SQ D's long time companion?
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 12, 2016, 11:36:31 PM
They are both neglected and dusty,,,,,,,,,,,,,,
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 13, 2016, 09:04:32 AM
I guess I didn't post it...

I got it running finally with a lot of tuning, adjusting, and cleaning. I like riding it most in the fall and winter.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 20, 2016, 05:08:50 PM
So, to catch folks up, DR- 1, Don- 0

Yep...While showing off I "Over-Wheelied" and managed to drop the bike on top of me.

So, yea, I have a broken foot and lots and lots of good riding weather is passing me by.

But knowing how I managed to do that and considering I normally wear combat boots, and was only in running shoes and shorts for the big "Tim-Ber" incident, I opted to add a good set of real riding boots to my closet.

The Forma Boots are not serious MX boots, but made for Adventure riding and I'll use them on my DR and on the Triumph Tiger
Title: Re: DR-650 Build Thread Part 1
Post by: JR on October 20, 2016, 05:28:50 PM
Yep, with those 2 heavywieghts and future spills will happen. Protect those feet!!
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 20, 2016, 05:42:06 PM
Rog!
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on October 20, 2016, 05:47:10 PM
Nice looking boots!
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on October 20, 2016, 07:53:13 PM
Nice boots, let me know how you like them once your foot gets back to a somewhat normal size & shape.

Funny, I guess I knew they made those just never knew anyone who spent money on them. Us farm boys always just wore our leather tall upper work boots. Plenty of spills when I was younger & never an issue out of them.
Title: DR-650 Build Thread Part 1
Post by: Bigdave_185 on October 21, 2016, 12:18:43 AM
I have these and love them(http://uploads.tapatalk-cdn.com/20161021/4188ca3f853aefb8069177b56a5359f1.jpg)


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Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on October 21, 2016, 07:42:40 AM
Flip flops , wife beater, camo shorts, no helmet. What could go wrong ?


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Title: Re: DR-650 Build Thread Part 1
Post by: kampfitt on October 21, 2016, 08:44:28 AM
LOL!! ;D ;D
Title: Re: DR-650 Build Thread Part 1
Post by: Sammconn on October 21, 2016, 08:53:55 AM
Flip flops , wife beater, camo shorts, no helmet. What could go wrong ?


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So true!
Nice looking boots there Don.
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on October 21, 2016, 09:04:01 AM
Flip flops , wife beater, camo shorts, no helmet. What could go wrong ?


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TRN, what are you describing here your preferred riding gear? Or was this what Big D was wearing in that ER pic his wife posted on FB?
Title: Re: DR-650 Build Thread Part 1
Post by: KensAuto on October 21, 2016, 09:57:36 AM
or both  ^^^
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on October 21, 2016, 11:37:51 AM
Paper pants!

That's what I remember from that night!
Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on October 21, 2016, 08:29:26 PM
Truth be told I went down on a street bike at 22 wearing shorts, a wife beater, and no helmet. The flip flops were a slight exaggeration that is a throw back to my dad getting his foot in the spokes of my cousins dirt bike back in the day. Ate most of the meat of the top of his toes.


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Title: Re: DR-650 Build Thread Part 1
Post by: RoadRamblerNJ on August 20, 2018, 11:20:44 PM
JR,
And question for ya
I am about to acquire one of thise 6.6 gallon Aceribus (or however you spell that name) fuel tanks
They tell me you can't paint it or put decals on it, because it seeps fumes from all over!
WHHHAAAAT?
Anyway, that is just a challenge.
I am going to paint it and decal it up with the cammo wrap
So me is thinkin' out loud
I'm thinking I spray the outer surface with an adhesion promoter first, then a primer, then a coat of paint. Perhaps even run some sort of sealant all around the inside of the tank to prevent this pesky migration of fuel molecules.
Concerns: Interior lines stuff flakes off and clogs the petcock/filter and we have sudden stoppage. Secondly, my paint and wrap falls off the tank just when and while some Harley guys are ridiculing the "Pretty Little" Jap bike...Not as a Harley owner, that I have ever done that....just sayin...
Kreme the inside of the tank.  Did that on a 30 yr old honda tank.  Fill it w/ a couple handfulls of small hex nuts with the prep and shake it around vigorously to loosen any flaky stuff.  Apply Kreme liquid primer, coat entire insides.   Kreme treatment next, pour in and tilt tank to cover everything. Let dry. Gets hard like porceline.  No more rust, etc.  Used to use this back in the 70's.  It works great.

PS: I think I finally stumbled onto the right forum after reading about this bike/truck build.  Been telling people for years about having a 4 stroke woods bike, bonoculars,fuel, food, ammo, water filters and spare parts for what you can't make. ie files, primers, springs, eye glasses. 
Falls on deaf ears here (NJ).  I'll be in TN asap.  Wifes already there.

https://www.google.com/search?q=cream+gas+tank+sealer&oq=creme+gas&aqs=chrome.1.69i57j0l3.10536j0j7&client=ms-android-verizon&sourceid=chrome-mobile&ie=UTF-8



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Title: Re: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 20, 2018, 11:42:39 PM
Rambler, unfortunately Don sold both adventure bikes last week

Now he’s on to “adventure heavy equipment”


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Title: Re: DR-650 Build Thread Part 1
Post by: RoadRamblerNJ on August 20, 2018, 11:56:38 PM
Thanks.  I just realized I answered a question from the absolute beginning of this thread.  And he had plastic tanks anyway.  I'm still going to TN!
Rambler, unfortunately Don sold both adventure bikes last week

Now he’s on to “adventure heavy equipment”


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Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on August 20, 2018, 11:59:36 PM
My in-laws live on Douglas Lake (part of TVA). They just came out for a visit and stated a lot of people are moving in from up east, places such as NJ.


On a serious note, can Don's knees handle the adventure bikes any longer?
Title: Re: DR-650 Build Thread Part 1
Post by: RoadRamblerNJ on August 21, 2018, 12:55:14 AM
My in-laws live on Douglas Lake (part of TVA). They just came out for a visit and stated a lot of people are moving in from up east, places such as NJ.


On a serious note, can Don's knees handle the adventure bikes any longer?
I can't wait to get out of this state.  It's becoming another California.  That, plus the fact the new Dem. Governor here is making most of my magazines illegal in a few months.

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Title: Re: DR-650 Build Thread Part 1
Post by: JR on August 21, 2018, 01:09:50 AM
I hear you Rambler, I need out of this state too. Half of what I like is illegal or going to be soon. They are even going to limit water use in a few years!

Don sold both bikes, How did I miss that? Looking at selling mine too, still a project but a runner.
Title: Re: DR-650 Build Thread Part 1
Post by: stlaser on August 21, 2018, 07:54:23 AM
JR, Charles was ribbing Don there a bit I believe.
Title: Re: DR-650 Build Thread Part 1
Post by: Flyin6 on August 21, 2018, 08:07:56 AM
Man, this old thread resurrected from the dead!

Yea, so after just missing that huge section of crane sitting in the slow lane of I-71, I finally admitted to myself that everytime I go out I am nearly hitting a "Road Gator" or being cut off by some lowered civic with a coffee can exhaust or some bimbo texting.

I may come back to the bike thing, dunno, but for now there is the farm which will soon crest the ridge to becoming a totally off grid self reliant place.

Heck, forget about EMP, monetary system collapse, killer virus, or zombies. These socialists are for sure going to drive a breakdown of society! I for sure just want to be anywhere they are not. I'm too old to get back to fighting in another war, although I surely would.

Anyway, bike for now is a no-go
Title: DR-650 Build Thread Part 1
Post by: TexasRedNeck on August 21, 2018, 08:13:46 AM
You boys should keep up. He mentioned it in the maladies and blood work thread


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