Building a DR650se

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

:-) :-)

goblin59 · 20-01-2021 2:52pm

Had a mate weld me up an adapter for a GSXR exhaust over the weekend,
Really need to learn to weld, and also have a place to do the welding.

New exhaust is nearly a 5th the weight of the old one,
So now have a titanium GSXR exhaust and a stainless steel midpipe,

new exhaust.jpeg

old exhaust.jpeg

adapter.jpeg

H_Lime · 20-01-2021 4:08pm

goblin59 wrote: »

Had a mate weld me up an adapter for a GSXR exhaust over the weekend,
Really need to learn to weld, and also have a place to do the welding.

New exhaust is nearly a 5th the weight of the old one,
So now have a titanium GSXR exhaust and a stainless steel midpipe,

new exhaust.jpeg

old exhaust.jpeg

adapter.jpeg

Good choice for a zorst on these as you know. Have it on both the bigs now, well a busa and a 40F0 gixer k1 one.
It's worthwhile extending the pipe past the flange mount about 10mm to stop the cannister gasket from being blasted by the exhaust pulses. Means it lasts and won't leak as quick.

goblin59 · 20-01-2021 5:06pm

H_Lime wrote: »

Good choice for a zorst on these as you know. Have it on both the bigs now, well a busa and a 40F0 gixer k1 one.
It's worthwhile extending the pipe past the flange mount about 10mm to stop the cannister gasket from being blasted by the exhaust pulses. Means it lasts and won't leak as quick.

Next time ill get him to do that! I get what you mean,
Problem is currently solved by not having the Cannister Gasket on there.

H_Lime · 20-01-2021 5:50pm

goblin59 wrote: »

Next time ill get him to do that! I get what you mean,
Problem is currently solved by not having the Cannister Gasket on there.

Lol at solved
If you use exhaust paste on your flange it should seal up but will be a mare to separate when set. Otherwise without the gasket it's liable blow and any blow on a big single=obnoxious banging on the over run no matter how much you play with the idle jets and or air screws.

goblin59 · 20-01-2021 6:05pm

H_Lime wrote: »

Lol at solved
If you use exhaust paste on your flange it should seal up but will be a mare to separate when set. Otherwise without the gasket it's liable blow and any blow on a big single=obnoxious banging on the over run no matter how much you play with the idle jets and or air screws.

I'll pop it off at some point then and try to fit a gasket in,
Dad has the procycle set up on his DR so I'll see how they get around it. I have Gasket paper here to that will make it easier

flashinthepan · 20-01-2021 6:52pm

goblin59 wrote: »

Had a mate weld me up an adapter for a GSXR exhaust over the weekend,
Really need to learn to weld, and also have a place to do the welding.

New exhaust is nearly a 5th the weight of the old one,
So now have a titanium GSXR exhaust and a stainless steel midpipe,

new exhaust.jpeg

old exhaust.jpeg

adapter.jpeg

Coming on leaps and bounds :-) well done

goblin59 · 20-01-2021 7:34pm

flashinthepan wrote: »

Coming on leaps and bounds :-) well done

cheers!
Post came earlier, so now I have front brakes too!

Will take the bike up the field tomorrow!

flashinthepan · 20-01-2021 10:46pm

goblin59 wrote: »

cheers!
Post came earlier, so now I have front brakes too!

That is something I need to sort on the V when I took the wheel off to get a new tyre a couple of weeks ago I noticed a rubber ring / seal coming off piston on the rear brake
I reckon it is a dust seal of some sort
Will have to get round to doing it when this muck weather clears off

goblin59 · 20-01-2021 11:02pm

flashinthepan wrote: »

That is something I need to sort on the V when I took the wheel off to get a new tyre a couple of weeks ago I noticed a rubber ring / seal coming off piston on the rear brake
I reckon it is a dust seal of some sort
Will have to get round to doing it when this muck weather clears off

once you have the new stuff it wasn't actually too bad to do.
Its a little messy in terms of dot4 going everywhere.
I think the front on the BMW might need it done too.

I've replaced the fluid with synthetic and have a speed bleeder, so shouldn't have to touch my brake hydraulics for a long time hopefully.

flashinthepan · 21-01-2021 7:15pm

goblin59 wrote: »

once you have the new stuff it wasn't actually too bad to do.
Its a little messy in terms of dot4 going everywhere.
I think the front on the BMW might need it done too.

I've replaced the fluid with synthetic and have a speed bleeder, so shouldn't have to touch my brake hydraulics for a long time hopefully.

I had flushed the rear when I got the bike as the brake may as well not have been there at all
But If I was honest the disc could prob do with being replaced also as it is badly scored and the pin that the pad slides on has a wear groove from lack of any grease / lubricant

I did see a thread where the Disc and caliper were swapped out for one from the V1000 and a new custom brake hose

Or I could maybe pick up a new disc and braided line with new pads would prob be a cheaper option

Building a DR650se

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