Author Topic: DR-650 Build Thread Part 1 (Read 130936 times)

JR · « **Reply #250 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

Flyin6 · « **Reply #251 on:** September 17, 2015, 02:58:25 PM »

Quote from: 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

Yep, this one runs
Rode it a couple days ago

TexasRedNeck · « **Reply #252 on:** September 17, 2015, 08:44:42 PM »

Don, other than looking more ninja like, what are the benefits of the new fender?

Flyin6 · « **Reply #253 on:** September 17, 2015, 10:43:00 PM »

Quote from: TexasRedNeck on September 17, 2015, 08:44:42 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

Flyin6 · « **Reply #254 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

Flyin6 · « **Reply #255 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

Flyin6 · « **Reply #256 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

Flyin6 · « **Reply #257 on:** September 17, 2015, 10:48:05 PM »

Fits like it belongs there

TexasRedNeck · « **Reply #258 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"

Flyin6 · « **Reply #259 on:** September 17, 2015, 10:49:11 PM »

Then with 4 carefully drilled holes, the ninja fender is bolted home

Flyin6 · « **Reply #260 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

Flyin6 · « **Reply #261 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

Flyin6 · « **Reply #262 on:** September 17, 2015, 10:59:19 PM »

And this is how all that fits and works

Flyin6 · « **Reply #263 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.

Flyin6 · « **Reply #264 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

Flyin6 · « **Reply #265 on:** September 17, 2015, 11:04:01 PM »

Finally, on my "Easy" day, I undercoated the new kick stand foot I had welded on

Flyin6 · « **Reply #266 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.......

Flyin6 · « **Reply #267 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:

Flyin6 · « **Reply #268 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

Flyin6 · « **Reply #269 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

Flyin6 · « **Reply #270 on:** September 20, 2015, 10:54:34 PM »

Before the teardown

Flyin6 · « **Reply #271 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

Flyin6 · « **Reply #272 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

Flyin6 · « **Reply #273 on:** September 20, 2015, 10:59:16 PM »

There are a host of parts like this air filter/breather which will not be reused

Flyin6 · « **Reply #274 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

Flyin6 · « **Reply #275 on:** September 20, 2015, 11:01:36 PM »

New and old

Flyin6 · « **Reply #276 on:** September 20, 2015, 11:03:10 PM »

The master cyl is pretty small, but is in the way, so it gets moved

Flyin6 · « **Reply #277 on:** September 20, 2015, 11:04:29 PM »

The carb mount on the head has some rubber tabs which need to be trimmed away

Flyin6 · « **Reply #278 on:** September 20, 2015, 11:05:53 PM »

Then I pulled the stock Air Box to modify it

Flyin6 · « **Reply #279 on:** September 20, 2015, 11:07:38 PM »

Out comes the stock air filter

And gets installed in the trash

Flyin6 · « **Reply #280 on:** September 20, 2015, 11:09:00 PM »

The snorkel is pulled next

Flyin6 · « **Reply #281 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

Flyin6 · « **Reply #282 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

Flyin6 · « **Reply #283 on:** September 20, 2015, 11:13:57 PM »

Being an on/off road bike, I left the FOD screen intact

Flyin6 · « **Reply #284 on:** September 20, 2015, 11:15:46 PM »

Then the new carb and the air box is installed

Flyin6 · « **Reply #285 on:** September 20, 2015, 11:17:07 PM »

Then the old throttle cables were replaced with the new ones

Flyin6 · « **Reply #286 on:** September 20, 2015, 11:18:34 PM »

The cables are hooked up and adjusted here and the air box buttoned up

Flyin6 · « **Reply #287 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!

Flyin6 · « **Reply #288 on:** September 20, 2015, 11:21:51 PM »

Here is the stuff which is not reused or has been replaced!

Flyin6 · « **Reply #289 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

BobbyB · « **Reply #290 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?

JR · « **Reply #291 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.

Flyin6 · « **Reply #292 on:** September 21, 2015, 08:38:55 AM »

Quote from: 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?

It's rideable. Should see a farm trip or two before cold weather.

Flyin6 · « **Reply #293 on:** September 21, 2015, 08:41:32 AM »

Quote from: 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.

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!

cudakidd53 · « **Reply #294 on:** September 21, 2015, 04:09:05 PM »

Really nice work! Suggestion: Keep old parts for SHTF spares- price is right!

Dawg25385 · « **Reply #295 on:** September 21, 2015, 04:24:24 PM »

Quote from: Flyin6 on September 21, 2015, 08:41:32 AM

...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!

TexasRedNeck · « **Reply #296 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?

Flyin6 · « **Reply #297 on:** September 21, 2015, 10:27:12 PM »

Quote from: Dawg25385 on September 21, 2015, 04:24:24 PM

Quote from: Flyin6 on September 21, 2015, 08:41:32 AM
...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)

Flyin6 · « **Reply #298 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.

Flyin6 · « **Reply #299 on:** September 21, 2015, 10:31:58 PM »

Adjustable vents everywhere!