Building a DR650se

goblin59 · 18-12-2020 12:49pm #1

Following Lightnings idea to do his own thread for the restoration of his NSR125
I'll keep the rebuild of the DR650se on its own thread.
The frame was an eBay purchase, the bike was crashed and bent, but a guy near Fermanagh works on Motocross bikes and has a jig for straightening the frames out.

The Engine was off another crash, but the frame was cut away.

Currently the engine is stuck onto the old frame and being a pain in the arse to free up.

Spent the last two days trying to free it.

goblin59 · 18-12-2020 12:53pm

I haven't been able to upload the photos properly unfortunately with the preview.
I had the frame blasted and powder coated as well as it was in a right state.

Got new Renthal handlebars for the bike, and waiting on procycle to ship some Ricor Intimidators for the Forks.

I've also done the NSU fix with the racing screws and safety wire.

flashinthepan · 18-12-2020 2:19pm

If it was easy everyone would be doing it :-)

goblin59 · 18-12-2020 3:53pm

flashinthepan wrote: »

If it was easy everyone would be doing it :-)

Honestly the hardest part has been freeing that stupid Engine mounting bolt, its M10x240mm and its melded itself to the engine casing.

I've 2 other DR650se in the house that I can look at to check stuff over.
The worse case scenario is there's another spare engine in the house so I'll swap all the good bits from this engine over into that engine.

I've only been on bikes since last November, so this was the best way to learn how they work xD plus we're bored!

flashinthepan · 18-12-2020 4:31pm

goblin59 wrote: »

Honestly the hardest part has been freeing that stupid Engine mounting bolt, its M10x240mm and its melded itself to the engine casing.

I've 2 other DR650se in the house that I can look at to check stuff over.
The worse case scenario is there's another spare engine in the house so I'll swap all the good bits from this engine over into that engine.

I've only been on bikes since last November, so this was the best way to learn how they work xD plus we're bored!

I have had a little success with the freezing spray :-)

goblin59 · 18-12-2020 6:21pm

flashinthepan wrote: »

I have had a little success with the freezing spray :-)

Got it out in the end,
we ended up drilling it out gradually until it just popped out!

Have a new A4-80 bolt on the way, and going to make sure its well greased up before going in to stop this happening again!

flashinthepan · 19-12-2020 12:27am

goblin59 wrote: »

going to make sure its well greased up before going in to stop this happening again!

H_Lime · 19-12-2020 6:59pm

Bummer on the seized mounts. British bike I'm gona guess?
What are the wearing faces of the rockers like on that motor and can you feel any play on the crank?

goblin59 · 19-12-2020 7:44pm

H_Lime wrote: »

Bummer on the seized mounts. British bike I'm gona guess?
What are the wearing faces of the rockers like on that motor and can you feel any play on the crank?

Yeah was a British Reg bike, I don't think that bolt had ever been undone since the bike was made in 1998
It was easier to do alot of the engine checks and set up in the cut frame as we had full access to it, was only when it came to swapping it over that we noticed the bolt.

The rockers and crank are seem to be in really good condition, same with all the internal gears including the plastic oil pump gear
I didn't take a crank cover off, but we removed the billet plug (with a chisel) and got the crank to turn by hand.
Checked the compression and tappets too.
had a replacement Billet plug already, apparently its a common problem.

I've new sprockets, chain, oil filter and steering bearings arriving next week.
In the meantime, I'll be installing the internals and M-unit

goblin59 · 30-12-2020 8:01pm

Got ignition today on the bike,
Spent the last 3 days going over the ignition circuit to get it working with the Motogadget M unit.

The DR650se has a CDI and ignition solenoid, but the CDI won't start without a 100ohm resistor (anti theft system) and I had to by pass all the switches on the bike.

Main reason it took 3 days was that one of the sockets on the ignition coil wasn't reading any resistance, so it wouldn't spark.
Had a spare so once that was replaced it started again

flashinthepan · 31-12-2020 9:00am

goblin59 wrote: »

Got ignition today on the bike,
Spent the last 3 days going over the ignition circuit to get it working with the Motogadget M unit.

The DR650se has a CDI and ignition solenoid, but the CDI won't start without a 100ohm resistor (anti theft system) and I had to by pass all the switches on the bike.

Main reason it took 3 days was that one of the sockets on the ignition coil wasn't reading any resistance, so it wouldn't spark.
Had a spare so once that was replaced it started again

Well done
It must be a great feeling when you have taken something to bits and put it back together and it fires up :-)
Great work

goblin59 · 31-12-2020 12:17pm

flashinthepan wrote: »

Well done
It must be a great feeling when you have taken something to bits and put it back together and it fires up :-)
Great work

Definitely!
Except for the shock from the spark xD

flashinthepan · 31-12-2020 6:11pm

goblin59 wrote: »

Definitely!
Except for the shock from the spark xD

That takes me back a few years :-)
Newer cars don't have HT leads anymore so no opportunity for a zap trying to find the plug that's not firing

You see some older bikes with HT leads but I would imagine most have coils nowdays :-)

goblin59 · 31-12-2020 7:11pm

flashinthepan wrote: »

That takes me back a few years :-)
Newer cars don't have HT leads anymore so no opportunity for a zap trying to find the plug that's not firing

You see some older bikes with HT leads but I would imagine most have coils nowdays :-)

Yeah the bike was made in 1998, not a clue about the engine! it was also an eBay purchase.

flashinthepan · 31-12-2020 7:19pm

Wow that is coming along really well :-)
Well done keep up the good work
J

goblin59 · 31-12-2020 7:29pm

flashinthepan wrote: »

Wow that is coming along really well :-)
Well done keep up the good work
J

Cheers!
I'm just glad it works!
Going to be interesting though when its running, some of the standard mods for this bike is disabling the safety features as they're the weak point for the bike, especially the side stand switch which had a tendency to stick and stop the bike mid journey over **** roads
But I installed a Bluetooth module that allows me to start the bike from my phone (if I wired it right) so there will be one day when I do that and the stupid thing does a flip as it wasn't in Neutral

flashinthepan · 31-12-2020 7:32pm

goblin59 wrote: »

Cheers!
I'm just glad it works!
Going to be interesting though when its running, some of the standard mods for this bike is disabling the safety features as they're the weak point for the bike, especially the side stand switch which had a tendency to stick and stop the bike mid journey over **** roads
But I installed a Bluetooth module that allows me to start the bike from my phone (if I wired it right) so there will be one day when I do that and the stupid thing does a flip as it wasn't in Neutral

Ohh that sounds great
Start the bike from the bed and the heated grips will be warm by the time you get on the bike
I love it :-)

goblin59 · 31-12-2020 8:35pm

flashinthepan wrote: »

Ohh that sounds great
Start the bike from the bed and the heated grips will be warm by the time you get on the bike
I love it :-)

haha unfortunatly bluetooth doesn't reach that far xD
I am putting oxford heated grips on though

flashinthepan · 01-01-2021 11:05am

goblin59 wrote: »

haha unfortunatly bluetooth doesn't reach that far xD
I am putting oxford heated grips on though

Put some oxford heated grips on mine yesterday
Have not had a chance to try them out yet had to trim about 5mm off the ends
They seem to heat up fairly quick but the throttle does not roll back as smoothly as it used to I might have cable tied it to tight

goblin59 · 01-01-2021 11:43am

flashinthepan wrote: »

Put some oxford heated grips on mine yesterday
Have not had a chance to try them out yet had to trim about 5mm off the ends
They seem to heat up fairly quick but the throttle does not roll back as smoothly as it used to I might have cable tied it to tight

I love the heated grips on the BMW.
yeah, they're quite long! I have a motion pro throttle tube on the way, the original tube that came with one of the parts isn't in great condition.

goblin59 · 02-01-2021 6:08pm

I decided to redo the entire loom again,
The main reason being the wire i ordered was too damn thick! so going to see on Monday if my local has 16awg multistrand wire in different colours.

New headlight arrived on Tuesday and then the VRT is wednesday! cutting it close.

goblin59 · 05-01-2021 6:00pm

Got the new headlight fitted on.
Havn't wired it up, going to start this weekend on the wiring, but nearly everything is there and ready to go.

Can see the orginal headlight on the 2014 DR, and then the new one I addded.
New one has built in DRLs and Indicators

flashinthepan · 06-01-2021 9:39pm

goblin59 wrote: »

Got the new headlight fitted on.
Havn't wired it up, going to start this weekend on the wiring, but nearly everything is there and ready to go.

Can see the orginal headlight on the 2014 DR, and then the new one I addded.
New one has built in DRLs and Indicators

I like the new one :-)
Should be a big improvement
Well done :-)

goblin59 · 06-01-2021 10:56pm

cheers!
VRT is done and the new wiring arrived today, so tomorrow is doing up the wires.
There's a lad in Omagh who does custom brake lines, so will get that on Friday.

goblin59 · 09-01-2021 7:10pm

Fitted the switches today, Absolute pain in the arse to get all the wires in the tube!
But looks awesome, probally a little over the top xD

Tomorrow I'll be wrapping up the loom, fixing the indicators and then fitting the heated grips.
Hopefully get the bike started on Monday

flashinthepan · 09-01-2021 7:17pm

goblin59 wrote: »

Fitted the switches today, Absolute pain in the arse to get all the wires in the tube!
But looks awesome, probally a little over the top xD

Tomorrow I'll be wrapping up the loom, fixing the indicators and then fitting the heated grips.
Hopefully get the bike started on Monday

looks fab alright
I would say worth the effort :-) well done

goblin59 · 09-01-2021 7:25pm

flashinthepan wrote: »

looks fab alright
I would say worth the effort :-) well done

I drilled an 8mm hole into the bars for each switch housing, would probally recommend going 10mm, getting the Mbutton into there sucked too!

Its definitly starting to come together, I'm fitting a touratech Garmin 595 locking mount as well to the bar

H_Lime · 09-01-2021 9:07pm

goblin59 wrote: »

Fitted the switches today, Absolute pain in the arse to get all the wires in the tube!
But looks awesome, probally a little over the top xD

Tomorrow I'll be wrapping up the loom, fixing the indicators and then fitting the heated grips.
Hopefully get the bike started on Monday

Really nicely done, you have the patience of a Saint and it'll be real tidy in the end..

fatbast · 09-01-2021 9:48pm

goblin59 wrote: »

I drilled an 8mm hole into the bars for each switch housing, would probally recommend going 10mm, getting the Mbutton into there sucked too!

Its definitly starting to come together, I'm fitting a touratech Garmin 595 locking mount as well to the bar

Fair play, I wouldn't have the skill or patience to do all of that. Wanted a trailie like that so just bought this ttr600. These old school trailies are ideal for town and back road use

goblin59 · 09-01-2021 11:03pm

yeah it took the full day just getting the switches wired in,
Tbh im mostly bored as **** these days too with the lack of concert work down haha.

Definitely looking forward to having this finished and on the road!

goblin59 · 12-01-2021 7:30pm

Went to start the engine for the first time today....
Starter motor Died, thankfully have a spare-one, so draining the oil tonight and installing the new one tomorrow and trying again.

Electrics are all wired up and have my phone paired up with the bike so I can test all the electrics using the phone

Zebbedee · 13-01-2021 9:55am

@goblin59
Excellent thread, really enjoying it.
Good on you for posting it.
Also it's so handy when you have a load of spares to hand (eg the starter motor)

goblin59 · 13-01-2021 11:23am

Zebbedee wrote: »

@goblin59
Excellent thread, really enjoying it.
Good on you for posting it.
Also it's so handy when you have a load of spares to hand (eg the starter motor)

Its been quite a fun project to do too! I went in with very little knowledge of the workings of bikes,
I have the Clymer Manual with me for this though. Wish Haynes did one too though, I prefer their layout.

They're Dad's favourite bike, so its handy when he bought so many random bits for his.
He got an Aussie import a while ago and bought spares as he wasn't sure of the condition of the bike, turns out it didn't need anything done.

H_Lime · 13-01-2021 1:56pm

Pics!
We need them!

goblin59 · 13-01-2021 7:29pm

I've one better for you!!
So had to do some more work on the bike today,
Got the spare starter motor installed today, took it apart first to clean and grease up though before it went in
Neutral switch didn't work, hard wired in a camera systems for front and back and then the bike didn't spark again. The spark issue was I had the spark plug grounded, but there is a 4th wire from the CDI that needs to connect to the grounding as well. It just seem to go off intot he wiring loom i did and i must have forgotten about it.

Next step is sort out the front calliper which is stuck, get new rear indicators and then on Monday I'll have insurance for the bike hopefully.

How do i up load a video btw ?

goblin59 · 14-01-2021 4:33pm

Cool, I'll do that now then.

I think I need to order a rebuild kit for the front brake unfortunately.
But other than that bike seems to work.

goblin59 · 14-01-2021 4:33pm

goblin59 · 14-01-2021 4:34pm

flashinthepan · 14-01-2021 6:01pm

goblin59 wrote: »

It's Alive :-)
Well done

goblin59 · 14-01-2021 6:29pm

flashinthepan wrote: »

It's Alive :-)
Well done

Didn't explode either xD
next step is fix the brake and get the bike insured

Zebbedee · 15-01-2021 11:57am

Well done on the rebuild.

There's nothing like the buzz of doing a build like that and hearing it fire up for the first time.

Looks like a really cool place to live too.
You have the perfect bike for it

goblin59 · 15-01-2021 1:18pm

Zebbedee wrote: »

Well done on the rebuild.

There's nothing like the buzz of doing a build like that and hearing it fire up for the first time.

Looks like a really cool place to live too.
You have the perfect bike for it

Yeah definitely! It was a great way to learn more about bikes too, I did my first IBT lesson in November 2019, so just over a year on bikes and didn't have much knowledge on maintaining them before this.

This is out in my parents house in the country side, we've alot of space out here and country roads but not a chance I'd get away with building this in Smithfield where I normally live!
I came up here end of the summer last year to do some construction work around the house

H_Lime · 15-01-2021 1:40pm

Sounds great!
Now the nice fettling begins like fine tuning of controls positioning, freeplay and biting points, aiming headlight yadayada....
Always best done with new consumables starting fresh. Mad how much a new clutch/throttle cable stretches in the first 50 mile, likewise chain. The pads seat in and brakes start to work better etc.
Well done on the build, you had a steep learning curve but twas no bother to you!
Ditch the oil and filter and inspect it carefully if that's a new to you motor and maybe check the valves again at the next service.

goblin59 · 15-01-2021 2:42pm

H_Lime wrote: »

Sounds great!
Now the nice fettling begins like fine tuning of controls positioning, freeplay and biting points, aiming headlight yadayada....
Always best done with new consumables starting fresh. Mad how much a new clutch/throttle cable stretches in the first 50 mile, likewise chain. The pads seat in and brakes start to work better etc.
Well done on the build, you had a steep learning curve but twas no bother to you!
Ditch the oil and filter and inspect it carefully if that's a new to you motor and maybe check the valves again at the next service.

The chainon the DR is incredibly ease to adjust, its great haha.
Seat is rock hard, I got a new one of the 2014DR, Dad ordered a seat concepts one.

Good point on the oil, Its easy enough to check as I can put the bike on the side to check the filter. Hopefully won't see any particles,
I've done the valves before it went in, but can test again too

flashinthepan · 15-01-2021 4:37pm

i would say you will have great fun out there in the muck & hills on that :-)

goblin59 · 15-01-2021 6:11pm

flashinthepan wrote: »

i would say you will have great fun out there in the muck & hills on that :-)

Definitely! some of the lads are talking about doing Morocco, so this would be the bike for that, easy to repair and less to break than if I took the BMW.

Plus it has a washable airfilter for if its really manky

flashinthepan · 15-01-2021 6:43pm

goblin59 wrote: »

Definitely! some of the lads are talking about doing Morocco, so this would be the bike for that, easy to repair and less to break than if I took the BMW.

Plus it has a washable airfilter for if its really manky

That would be an adventure alright :-) something to look forward to in 10 years time

goblin59 · 15-01-2021 7:31pm

flashinthepan wrote: »

That would be an adventure alright :-) something to look forward to in 10 years time

haha as much as I'd like to do it this year, yeah probably Easter or summer 2022

flashinthepan · 15-01-2021 8:23pm

goblin59 wrote: »

haha as much as I'd like to do it this year, yeah probably Easter or summer 2022

No chance we will be on lockdown number 22 by then :-)

goblin59 · 15-01-2021 8:30pm

flashinthepan wrote: »

No chance we will be on lockdown number 22 by then :-)

Don't you jinx it!! xD

flashinthepan · 15-01-2021 8:34pm

goblin59 wrote: »

Don't you jinx it!! xD

:-) :-)

Building a DR650se

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