Author Topic: DR-650 Build Thread Part 1 (Read 131038 times)

Flyin6 · « **Reply #350 on:** October 01, 2015, 10:35:23 PM »

The newer 14T sprocket is a tad smaller in diameter

Flyin6 · « **Reply #351 on:** October 01, 2015, 10:36:10 PM »

But fits right on like it was made for the bike!

Flyin6 · « **Reply #352 on:** October 01, 2015, 10:37:08 PM »

Then the case saver bolts on quickly and easily with just three allen head screws

Flyin6 · « **Reply #353 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!

TexasRedNeck · « **Reply #354 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....

JR · « **Reply #355 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.

Flyin6 · « **Reply #356 on:** October 02, 2015, 10:21:33 AM »

Quote from: JR on October 02, 2015, 01:40:06 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

Flyin6 · « **Reply #357 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?

TexasRedNeck · « **Reply #358 on:** October 02, 2015, 12:42:27 PM »

Barely. My conversion experience was 8/24/2003. Perhaps He was sending a message.

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JR · « **Reply #359 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,,,,,,,,,,,,,,,,,,

Flyin6 · « **Reply #360 on:** October 02, 2015, 12:54:48 PM »

Quote from: 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,,,,,,,,,,,,,,,,,,

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...

JR · « **Reply #361 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!

Flyin6 · « **Reply #362 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!

JR · « **Reply #363 on:** October 02, 2015, 03:25:32 PM »

TexasRedNeck · « **Reply #364 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

Flyin6 · « **Reply #365 on:** October 02, 2015, 07:10:40 PM »

Quote from: 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

Mine had brakes!
Engine compression and my boots!

Flyin6 · « **Reply #366 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

Flyin6 · « **Reply #367 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

Flyin6 · « **Reply #368 on:** October 17, 2015, 08:14:17 PM »

Off with the rubber mounted stockers

Flyin6 · « **Reply #369 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

Flyin6 · « **Reply #370 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

JR · « **Reply #371 on:** October 17, 2015, 08:18:20 PM »

Are they supposed to go backwards? I would say forward or straight down,,,,,,,,,,

Flyin6 · « **Reply #372 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...

Flyin6 · « **Reply #373 on:** October 17, 2015, 08:20:23 PM »

Quote from: JR on October 17, 2015, 08:18:20 PM

Are they supposed to go backwards? I would say forward or straight down,,,,,,,,,,

Roger that...Backward

Forward would crowd the gearshift a lot

JR · « **Reply #374 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?

JR · « **Reply #375 on:** October 17, 2015, 08:23:15 PM »

Quote from: 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!

Leaving a trail, doesn't sound like a sane idea. Unless you ride over a zombie or 2.

Flyin6 · « **Reply #376 on:** October 18, 2015, 06:54:51 PM »

Took the DR out for a ride today

It was 47F

Result:

TexasRedNeck · « **Reply #377 on:** October 18, 2015, 08:02:27 PM »

The Kentucky version of The Stig.....

stlaser · « **Reply #378 on:** October 18, 2015, 08:18:21 PM »

Quote from: TexasRedNeck on October 18, 2015, 08:02:27 PM

The Kentucky version of The Stig.....

I think its the KY version of DOG (Dead Old Guy)....... ;)

Flyin6 · « **Reply #379 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

Flyin6 · « **Reply #380 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

Flyin6 · « **Reply #381 on:** November 03, 2015, 07:01:59 PM »

And just like that, it was installed

Flyin6 · « **Reply #382 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

Flyin6 · « **Reply #383 on:** November 03, 2015, 07:04:01 PM »

The one remaining stock rectangular mirror is about to go bye-bye

Flyin6 · « **Reply #384 on:** November 03, 2015, 07:05:11 PM »

With a twist of a bolt and the slight of hand, it was installed

Flyin6 · « **Reply #385 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

Flyin6 · « **Reply #386 on:** November 03, 2015, 07:08:05 PM »

Two screws and that chore was done

Flyin6 · « **Reply #387 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

Flyin6 · « **Reply #388 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

Flyin6 · « **Reply #389 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

Flyin6 · « **Reply #390 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!

Flyin6 · « **Reply #391 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

TexasRedNeck · « **Reply #392 on:** November 03, 2015, 07:45:22 PM »

shed some more light on the different cross bit screws. News to me

Flyin6 · « **Reply #393 on:** November 04, 2015, 09:25:49 AM »

Quote from: TexasRedNeck on November 03, 2015, 07:45:22 PM

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

TexasRedNeck · « **Reply #394 on:** November 04, 2015, 12:31:22 PM »

L I B, M R Jap screwdrivers.

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cudakidd53 · « **Reply #395 on:** November 04, 2015, 04:11:25 PM »

Once again, getting screwed by foreign goods.......literally! >:(

Flyin6 · « **Reply #396 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.

Flyin6 · « **Reply #397 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!

Armalite · « **Reply #398 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.

cudakidd53 · « **Reply #399 on:** November 17, 2015, 04:00:54 PM »

Quote from: 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!

I thought you were just trying to illustrate the upside down dump event!