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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #100 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
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Offline BobbyB

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Re: DR-650 Build Thread
« Reply #101 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....
So, Bobby...being the calculating trained warrior NCO that you are.  Take the appropriate action, Execute!
your standard grunt level CQB is just putting rounds and rounds on scary stuff till it stops scaring you!

Offline Flyin6

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Re: DR-650 Build Thread
« Reply #102 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!
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #103 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
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #104 on: September 25, 2014, 07:39:38 PM »
Wait till you see that big honkin' tank go on tomorrow

Dwarfs the stocker!
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Offline BobbyB

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Re: DR-650 Build Thread
« Reply #105 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.
So, Bobby...being the calculating trained warrior NCO that you are.  Take the appropriate action, Execute!
your standard grunt level CQB is just putting rounds and rounds on scary stuff till it stops scaring you!

Offline Flyin6

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Re: DR-650 Build Thread
« Reply #106 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
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #107 on: September 26, 2014, 02:20:28 PM »
I added some hand guards as well

I started with replacing the bent brake lever
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #108 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
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #109 on: September 26, 2014, 02:23:28 PM »
The thing locks into the end of the handlebar with a largish expansion bolt
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #110 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
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #111 on: September 26, 2014, 02:26:59 PM »
The aluminum bar looks like it will protect quite well
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Offline Flyin6

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Re: DR-650 Build Thread
« Reply #112 on: September 26, 2014, 02:28:12 PM »
It all looks like it will perform its function quite well
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Offline moto123

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Re: DR-650 Build Thread Part 1
« Reply #113 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.

Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #114 on: September 29, 2014, 03:27:27 PM »
Good News!
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #115 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #116 on: September 29, 2014, 03:30:24 PM »
Which I painted black, John Deere chassis blitz black to be exact
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #117 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
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Re: DR-650 Build Thread Part 1
« Reply #118 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #119 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #120 on: October 02, 2014, 04:15:56 PM »
Then the puney 3.3 gallon stock tank
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #121 on: October 02, 2014, 04:17:42 PM »
The new tank is 6.6 gallons, nearly twice the size
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #122 on: October 02, 2014, 04:19:02 PM »
Quality hardware was included of course
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #123 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
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Re: DR-650 Build Thread Part 1
« Reply #124 on: October 02, 2014, 04:23:59 PM »
Then I temporarily mounted the tank up
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Re: DR-650 Build Thread Part 1
« Reply #125 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #126 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!
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Re: DR-650 Build Thread Part 1
« Reply #127 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #128 on: October 02, 2014, 04:32:24 PM »
Then I simply bolted it back on, then topped it off with the new sergeant seat
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #129 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #130 on: October 02, 2014, 04:34:52 PM »
And that would conclude a short and sweet build day 5 on the DR
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Offline JR

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Re: DR-650 Build Thread Part 1
« Reply #131 on: October 02, 2014, 11:47:34 PM »
How is the power with the exhaust?

Wanated ask about the headlight too, love the LED.
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #132 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!
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Offline turn_one

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Re: DR-650 Build Thread Part 1
« Reply #133 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:

  • Michelin Bib Mousse - This is a foam donut that takes the place of a tube and never goes flat.  Downside is that after extended road miles heat can build from friction between the mousse and tire and break the foam down.  And a little heavier than a standard tube https://www.rockymountainatvmc.com/p/864/3342/Michelin-Bib-Mousse-Foam-Tube
  • Heavy duty or Ultra heavy duty tubes - Better protection against pinch flats but never will stand up to a nail.  Also a little heavier
  • Tubliss system - A bicycle style inner tube with a robust outer tube that cover your spoke holes.  Allows you to run low air pressure and no traditional tube.  If your tire gets a puncture just plug it.  http://tubliss.com/

Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #134 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!
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Offline BobbyB

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Re: DR-650 Build Thread Part 1
« Reply #135 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.
So, Bobby...being the calculating trained warrior NCO that you are.  Take the appropriate action, Execute!
your standard grunt level CQB is just putting rounds and rounds on scary stuff till it stops scaring you!

Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #136 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:
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #137 on: October 04, 2014, 04:37:53 PM »
Here's the victim and the start point:
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #138 on: October 04, 2014, 04:39:40 PM »
Removal requires the unbolting of the lower scissors linkage and some well shrouded bolts and nuts
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #139 on: October 04, 2014, 04:41:08 PM »
To get to this point takes a bit of work, but no too awful bad
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #140 on: October 04, 2014, 04:41:54 PM »
Stock air box next is removed to gain access to the upper shock bolt
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #141 on: October 04, 2014, 04:42:37 PM »
Yielding this:
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #142 on: October 04, 2014, 04:43:54 PM »
The upper bolt comes out easily, and here is a comparo shot of each shock
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #143 on: October 04, 2014, 04:45:15 PM »
Looks a little barren in there:
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Re: DR-650 Build Thread Part 1
« Reply #144 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
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Re: DR-650 Build Thread Part 1
« Reply #145 on: October 04, 2014, 04:48:22 PM »
With some struggle, the shock fell back into it's happy place
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #146 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!
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Offline JR

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Re: DR-650 Build Thread Part 1
« Reply #147 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,,,,,,,,,,,,,,,
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #148 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
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Offline Flyin6

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Re: DR-650 Build Thread Part 1
« Reply #149 on: October 07, 2014, 09:58:45 AM »
Teaser...A short view into the future:
Site owner    Isaiah 6:8, Psalm 91 
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