Tales from the Emporium

[timg]

Hey I'm not complaining mind.
If I get a nail in a tyre that's exactly how I'd like it to be :D .... unlike this un, aye?:shit::eek::nono::mad::angry2::crybaby:

[buggsubique]

20 min later it's all back together...
With 3 big pinch holes :stupid:



Yeah I thought I was the tyre changing legend till I installed a standard tube instead of my usual heavy duty ones...pinch holes all through it... Heavy duty tubes are a piece of piss though and put up with my lack of grace...

[JATZ]

Yeah I thought I was the tyre changing legend till I installed a standard tube instead of my usual heavy duty ones...pinch holes all through it... Heavy duty tubes are a piece of piss though and put up with my lack of grace...

Personaly. I try to use just the very very tip of the lever when putin the tyre back on, discovered this after completly munting a tube first time round, also use hevy duty tubes.
The MT21 I put on the front I can just about get all the way on by hand, it''s those pesky Czech tyres I struggle with.

[NordieBoy]

Found this and just had to have it :D
Check out the wording in the 2nd pic...

<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/slides/20081112-141904.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/thumbs/20081112-141904.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/slides/20081112-141921.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/thumbs/20081112-141921.jpg></a>

[JATZ]

Looks like usefull stuff, for tyre changes, and for the kids, Santa could bring them some for Xmas:laugh:
BTW where'd ya get it ?

[Woodman]

haven't had a flat for ages, but these ramblings reminded me of a sort of tube some enduro guys used years ago. It had ends e.g. it was not a full circle and when it was inflated in the tyre the ends butted together. The great thing about them was that you did not have to take your wheel off, just lay the bike down, take one side of the tyre off, fit the tube etc etc. Does anyone know if they are still available? Haven.t looked online yet.

[NordieBoy]

Looks like usefull stuff, for tyre changes, and for the kids, Santa could bring them some for Xmas
BTW where'd ya get it ?
Nelson Motorcycle Centre.
I'm not going to use it :rolleyes:

[Woodman]

Nelson Motorcycle Centre.
I'm not going to use it :rolleyes:

And there was me thinkin they were unavailable, might have a look this weekend. Good thing to stick in me goody bag along with all the other shit i never use, cos you just never know when you will need it.

[NordieBoy]

And there was me thinkin they were unavailable, might have a look this weekend. Good thing to stick in me goody bag along with all the other shit i never use, cos you just never know when you will need it.

They probably are unavailable :Oops:

[Woodman]

They probably are unavailable :Oops:

Pay attention Woodman

[Moki]

haven't had a flat for ages, but these ramblings reminded me of a sort of tube some enduro guys used years ago. It had ends e.g. it was not a full circle and when it was inflated in the tyre the ends butted together. The great thing about them was that you did not have to take your wheel off, just lay the bike down, take one side of the tyre off, fit the tube etc etc. Does anyone know if they are still available? Haven.t looked online yet.

I think these are called "mousses" ... Don't know where you get them though.

[Oscar]

haven't had a flat for ages, but these ramblings reminded me of a sort of tube some enduro guys used years ago. It had ends e.g. it was not a full circle and when it was inflated in the tyre the ends butted together. The great thing about them was that you did not have to take your wheel off, just lay the bike down, take one side of the tyre off, fit the tube etc etc. Does anyone know if they are still available? Haven.t looked online yet.

I had one 'o dose...
Can't remember where it came from, though.

Also had the tubes with the valve on the side (moves with the tyre at low pressures, so as not to tear).

[Oscar]

I think these are called "mousses" ... Don't know where you get them though.

Nah, he's talking about actual tubes.
You're talking Michelin Bib Mousse.

'Kin expensive, not practical for everyday use:
http://www.dirtguide.co.nz/content/kernel_public_catalogue_indexViewEntry.aspx?intKer nel_catalogueEntry_PK=1867

[Oscar]

Found this and just had to have it :D
Check out the wording in the 2nd pic...

<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/slides/20081112-141904.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/thumbs/20081112-141904.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/slides/20081112-141921.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/thumbs/20081112-141921.jpg></a>

???
What's wrong with dishwashing liquid?

[NordieBoy]

???
What's wrong with dishwashing liquid?

Dishwashing liquid dosn't say "Do not keep out of reach of children".

[NordieBoy]

The brass one is OEM the other is the Suzuki replacement.
The brass one is noticeably ovalised at the top.

<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081121%20New%20Emulsion%20Tube/slides/20081121-094829.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081121%20New%20Emulsion%20Tube/thumbs/20081121-094829.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081121%20New%20Emulsion%20Tube/slides/20081121-094755.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081121%20New%20Emulsion%20Tube/thumbs/20081121-094755.jpg></a>

Changed the jetting from DJ155 main and needle 2nd from top to my favorite old SuperTrapp settings of DJ160 and 3rd from top.
Now to try it out.

[warewolf]

The brass one is noticeably ovalised at the top.Mwahaha that one's not ovalised... it's completely POKED! One-half to one-third of that wear is enough to cause problems. You've probably been masking the issue with your constant fiddling.

[Transalper]

Dishwashing liquid dosn't say "Do not keep out of reach of children".
I have heard the dishwashing liquid contributes to the alloy crossion, all that white scabbyness to the inside of the rims.
I wipe a bit of wd40 on the rim now. Dont reckon my tyres last long enough to be hurt by it and don't seem to be able to push the bike hard enough to have them tyres spin under the rimlocks.

[NordieBoy]

Mwahaha that one's not ovalised... it's completely POKED! One-half to one-third of that wear is enough to cause problems. You've probably been masking the issue with your constant fiddling.

With my constant adjusting to compensate for the jet getting progressively worse you mean :D

DJ160 main and needle 3rd from top is too rich down low at the moment.

Lester is going to weld a nut onto the mid-pipe on Monday so we can get some gas readings.

[NordieBoy]

I have heard the dishwashing liquid contributes to the alloy crossion, all that white scabbyness to the inside of the rims.
I wipe a bit of wd40 on the rim now. Dont reckon my tyres last long enough to be hurt by it and don't seem to be able to push the bike hard enough to have them tyres spin under the rimlocks.

Now I've got the beadcream/levers/patches/spare tubes I probably won't get another puncture again.

Unless it's the day I leave them at home...

PS. Even with my riding style the rear MT21 isn't going to last long...
I think I'll bung another SR244 on there until the wallet recovers from the Pirelli hit and then try an E09.

[Transalper]

Saw MarkS today as we were about 1/4 way in to the Porika Track from Howard Valley. He was on the KLR with luggage and looked like running E09s.
He had come up from the lake end and was going out toward the Howard.

[NordieBoy]

Next time you see him hassle him about stalling the KLR on the Maungatapu :D

I thought an auto clutch made stalling unpossible...

[cobber]

Now I've got the beadcream/levers/patches/spare tubes I probably won't get another puncture again.

Unless it's the day I leave them at home...

PS. Even with my riding style the rear MT21 isn't going to last long...
I think I'll bung another SR244 on there until the wallet recovers from the Pirelli hit and then try an E09.

Fan, hate to spoil the day but dont puctures come in threes like most other problems or if you count the pinches you might be ok for awhile, especially with all the repair gear sorted,

[NordieBoy]

So I should be due for another puncture in oh... 2012

[marks]

Saw MarkS today as we were about 1/4 way in to the Porika Track from Howard Valley. He was on the KLR with luggage and looked like running E09s.
He had come up from the lake end and was going out toward the Howard.

Was good to see you guys at such an out of the way place.

TKC on front E09 on back

how did you guys find the south end of the Porika?


Next time you see him hassle him about stalling the KLR on the Maungatapu :D

I thought an auto clutch made stalling unpossible...

I'm special - I can stall anything - actually I think the low speed jetting needs a fiddle

[Transalper]

...
how did you guys find the south end of the Porika? ...
Good When we got down to the lake we turned around and climbed back up, then turned around again and went back down to the lake again.
I reckon there is not as much chunky loose stuff on the south slopes as the last few times I've done it. That or I was just having a really good run and on balding E07 rear/ good knobby front combo.

[NordieBoy]

Ok....

I guessed at some settings for the setup I'd need with the new emulsion tube and went from:
DJ155, needle 2nd from top, Pilot 45, Pilot Air 1.2, worn emulsion tube.
to
DJ160, needle 4th from top, Pilot 45, Pilot Air 1.2, new emulsion tube.

The dyno graph showed I'm down .5 HP and 2 ft/lbs on the best SuperTrapp settings.

But the SuperTrapp run was done with worn TW42's not good MT21's.

My guess for jetting was pretty close :D
Lester says I should drop the needle 0.5mm.

Check out the Air/Fuel - The new one is the red one...

[warewolf]

My guess for jetting was pretty close :D
Lester says I should drop the needle 0.5mm.

Check out the Air/Fuel - The new one is the red one...Nice line! So you need to go a bit leaner (higher air/fuel ratio)... by dropping the needle?

[NordieBoy]

That's the one.
Leaner by half a clip.

We did 3 runs to make sure we wern't getting a bad reading. Lester was worried the line was too flat :D

I am rapt how smooth that line is.

Soooo....
Current status is:

Snorkle removed and airbox top opened
TwinAir filter
Backfire screen removed
NGK CR9EK twin electrode plugs
Header weld ground flush
Hindle mid-pipe
GSXR600 muffler
New non-brass emulsion tube
DJ160 main
DJ needle 4th from top
45 pilot (up 1 size)
1.2 pilot air (up 2 sizes)
3.5 winds cut off the carb slide spring
2nd hole drilled in carb slide

[NordieBoy]

Ummm... :o

When I fitted the new emulsion tube I set it up as DJ160, needle 3rd from top and it was a bit boggy so I opened it up again and intended to drop the needle a notch to 2nd from top and accidentally went the wrong way and made it even richer at 4th from top which is how it dyno'd.

Now, needing to make it 1/2 a notch leaner I opened it up and the little 0.5mm dynojet washer that sits on top of the needle clip... was under the needle clip :oi-grr:

Putting it back on top is my 0.5mm adjustment :innocent:

[XF650]

Not sure if this helps you Fran - same motor but extra carb.
Since dyno, found it to be running a bit lean at high altitude. So have lowered the air box lid (reduced air intake) a smidgen, to compensate. Probably needs another dyno run to check.

[NordieBoy]

Holy crap that's rich down the bottom!
It'd be blowing black deisel smoke out the back!

More power than the DR's single carb.
That's why CCM used it as the base for their bikes.

They should richen up with altitude - less oxygen content/thinner air.
Over in the states they are finding the slightly modded DR's don't need the needle raised for those riding at altitude.

Really rich 3-3.5k
Really lean 4-6k
Nice 6.2-7k
Leans off again 7k to redline.

Wonder if that's a typical profile for the XF?

I'd be looking at either dropping the pilot size (blocked pilot-air maybe) to help the low revs and going up a size on the main to richen the mid/top?

Twin carbs are confusing.
The Nordie has a conventional top-pull carb one side and a CV on the other.

Shane asks if you've dropped the front sprocket a tooth yet :D

[XF650]

The XF carbs are a bitch to get at but yes, it is probably time to have another fiddle. Re-test on the local dyno not expensive either.

Tell Shane that 14th sprocket & better (EO9) tyres went on straight after the Porika incident.

[NordieBoy]

Tell Shane that 14th sprocket & better (EO9) tyres went on straight after the Porika incident.

He will be happy to hear that :D

[clint640]

Good stuff, nice to be able to back up the tinkerings with dyno info.

Last time I stripped down the BST40 on the 640 for a clean I noticed that the slide was pretty worn so I might give the carb a birthday at the next service; slide & slide guide, needle & needle jet at least. You haven't spotted a well priced rebuild kit for the Mikuni anywhere in your travels have ya?

Cheers
Clint

[NordieBoy]

Would you believe it?

The Nordie pillion pegs fit on the DR!
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Rear%20footpegs/slides/20081206-165746.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Rear%20footpegs/thumbs/20081206-165746.jpg></a>

And are 4cm lower!
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Rear%20footpegs/slides/20081206-165845.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Rear%20footpegs/thumbs/20081206-165845.jpg></a>

Not as much lower as the pre 96 DR pegs would be though :D
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Rear%20footpegs/slides/20081206-165934.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Rear%20footpegs/thumbs/20081206-165934.jpg></a>


Hmmm...
Wonder what other bits I can grab?

[NordieBoy]

Wonder what other bits I can grab?

Hmmmm....

Should bolt up and they're 1cm shorter than the stockers.
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Expensive%20thoughts.../slides/20081206-172145.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Expensive%20thoughts.../thumbs/20081206-172145.jpg></a>

Same size disc and pretty damn close sprocket to disc spacing too...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Expensive%20thoughts.../slides/20081206-172151.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081206%20Expensive%20thoughts.../thumbs/20081206-172151.jpg></a>

[NordieBoy]

Looks like replacing the 5W stock oil in the rear shock with 10W has done the trick.
The Bro took it around a MX track including jumps and says "it's 10x better" but now the front end is the weak link.

Emulators are the next suspension mod then after some lighting tweaks - Looking for an SV650 round headlight if my current idea doesn't pan out...



Oh, I also checked my revcounter after Shanes ride...
Maxed at 7400rpm bouncing off the limiter through the uphill bog section with no ill effects.
Good to know what it'll take and that my usual 5400-5600rpm max (120kph in top) is well within it's capabilities :D

[NordieBoy]

I finally complete a tyre change...

First I watched Neduro do a tyre change...
And then off to the gargre...


Breaking the bead was a bugger...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-154108-000009.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-154108-000009.jpg></a>

Finally had to use the mighty XR side stand to do the job.
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-155942-000010.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-155942-000010.jpg></a>

Off comes the MT21 and on goes the SR244.
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-161240-000012.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-161240-000012.jpg></a>

1st effort with the old Conti HD tube (outlasted 2*SR244, 1*TW42, 1*GP110 and 1*MT21) resulted in 2 pairs of pinch flats...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-163312-000013.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-163312-000013.jpg></a>

(Back to watch Neduro again...)

And the new Conti HD tube resulted in 1 pair of pinch flats...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-170252-000015.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-170252-000015.jpg></a>

(Neduro again...)

Which I managed to cover with 1 patch...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-174932-000016.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-174932-000016.jpg></a>

Finally on and holding pressure.
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081220-182624-000017.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081220-182624-000017.jpg></a>

Trueing it up without the rimlock...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081221-120458-000001.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081221-120458-000001.jpg></a>

Meant it was quite a bit lighter...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081221-121648-000002.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081221-121648-000002.jpg></a>

Aaaaannnnnnnnddddd done...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/slides/20081221-121724-000004.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081220%20Re-Tyring%20work/thumbs/20081221-121724-000004.jpg></a>

[Transalper]

Reckon you might have been a bit heavy handed or rushing a bit if you got pinch flats As you've probably discovered by now you just have to be careful how far in you stick your leavers and keep a tiny bit of air in the tube. I've done quite a few tyre changes now but never had an issue pinching tubes and nowdays I just run light duty tubes.

[NordieBoy]

I was actually taking it very slowly.
Pity there was no sun 'cause I could have used the help with the carcass of the SR244 which was all bolloxed up from being tied up in transport to Nelson.

I think I was letting the spoon part get too far past the bead and it was grabbing a bit of tube.

Hmmm... Lube the end of the spoon so it doesn't grip on the tube?

After the Dusty I'll reverse the front tyre to even up the wear and see how I go there.


PS: What tyre levers do you use?

[Transalper]

I lube up my tyre iorns with wd40, also once I get them in under the tyre I then pull them out far enough so they are just in enough to get the tyre without catching the tube before I start levering the tyre over the rim. I have one spoon type leaver which is harder to be careful with and a smaller leaver which has a nicer more user friendly end.

[NordieBoy]

I like the idea of Neduro's ones with the lip.
I've modded my straight lever to have a notch and I'll see how/if it helps.

[JATZ]

I like the idea of Neduro's ones with the lip.
I've modded my straight lever to have a notch and I'll see how/if it helps.

Can't leave any thing alone can you :Pokey:

BTW, where's the best place to get bits for these.Before xmas
http://i412.photobucket.com/albums/pp201/ztaj/115_1572.jpg

Got bored today and this seemed like a worthwhile pastime

Need needles,jets,slides

[warewolf]

Did you powder your nose, umm, the tube? Helps the tube to move around, de-stress and generally avoid getting pinched.

I will see if I can borrow my mate's KTM levers for 'show and tell' at the dusty butt BBQ (and maybe the DB itself) as they are the schizzz! They have a lip on the tip to hook the tyre getting it off, and a lip on the underside a little back from the tip to hook the rim getting it on. They make the job about as hard as changing mtb tyres.

[Transalper]

These 220mm motion pro (http://www.motionpro.com/motorcycle/partno/08-0003) ones are my good ones that I find are easier to use and easier to hook the tyre but not the tube with than my other tyre iorn which is a spoon/axel nut combo.

The ones in the Neduro pages look quite long. One issue with long iorns is that you can tend to use force to compensate for bad technique and that can bugger the beed. If you doubt this then just ask MattsDakar about his experiences with one paticular tyre he had briefly.

[NordieBoy]

These 220mm motion pro (http://www.motionpro.com/motorcycle/partno/08-0003) ones are my good ones that I find are easier to use and easier to hook the tyre but not the tube with than my other tyre iorn which is a spoon/axel nut combo.

Yep. I've got one of those and a spoon/axle nut pair in 19 and 24mm.

[NordieBoy]

Did you powder your nose, umm, the tube? Helps the tube to move around, de-stress and generally avoid getting pinched.

That would have helped but I also just checked the levers and they are quite sticky from dried lube and rubber and would have gripped the tube quite well.

That does not sound good on a second reading...

:buggerd:

[NordieBoy]

Can't leave any thing alone can you :Pokey:

BTW, where's the best place to get bits for these.Before xmas

Got bored today and this seemed like a worthwhile pastime

Need needles,jets,slides

Either Murray Thornes or Nelson Motorcycle Centre.

28mm BST's?
They look like cute little miniture versions of the DR & KTM carb :D

[Woodman]

These 220mm motion pro (http://www.motionpro.com/motorcycle/partno/08-0003) ones are my good ones that I find are easier to use and easier to hook the tyre but not the tube with than my other tyre iorn which is a spoon/axel nut combo.

The ones in the Neduro pages look quite long. One issue with long iorns is that you can tend to use force to compensate for bad technique and that can bugger the beed. If you doubt this then just ask MattsDakar about his experiences with one paticular tyre he had briefly.

Haha brings back memories of another time. I once snapped the bead on a brand new front knobbly the night before a hare scramble. It makes the tyre real easy to put on after that. Only got round the practice lap and come race time the tyre rolled right off the rim:doh: Spent the next 2 hours sitting on a fencepost watching the bikes go past. Lesson is use small levers and good technique, or befriend someone with a tyre machine.

[Transalper]

Nice one, Matts lesson was similar, new tyre stopped holding air when it cut the tube, think he got trailered home an hour in to what was an awesome full day out for the rest of us.

[talbertnz]

http://www.motionpro.com/images/items/08-0003.jpg

-Cold forged steel
-8.5 inch size is easy to carry and fits in most fanny packs


...fanny packs?????? :eek5: ....Woman only??????

[warewolf]

8.5", fits in fanny pack, women only...

Where do you put the batteries? :gob:

[NordieBoy]

This may not be ready by the time the DB rolls around but it should be good when it's done :D

[Transalper]

Didn't think the two day riders needed lights.
Looks good though. The DR250 Djebel had a big round bright good one a lot like that.:niceone:

[NordieBoy]

Didn't think the two day riders needed lights.

We may get delayed and end up going through the Porika in the dark :msn-wink:

Got the bi-xenon HID kit to go inside it too :eek:

It's a nice little 7" off an SV650.

[NordieBoy]

I hate it when I get bored...

It's done.
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081224%20SV650%20Lighting/slides/20081225-172926-000003.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081224%20SV650%20Lighting/thumbs/20081225-172926-000003.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081224%20SV650%20Lighting/slides/20081225-182928-000004.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081224%20SV650%20Lighting/thumbs/20081225-182928-000004.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081224%20SV650%20Lighting/slides/20081225-183012-000007.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20081224%20SV650%20Lighting/thumbs/20081225-183012-000007.jpg></a>

Just need to get some better bolts/washers/nylocks and it'll work long term and I'll make a new pair of side mounts for it with a bit more meat around the bolt holes and some room to bolt a fairing/top piece to hide the wireing.
Only got a Phillips 55/60W +50 in at the moment.

Thanks Devil :D

[NordieBoy]

It works too :D

<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/Trips/20081225%20Maungatapu%20Light%20test/slides/20081225-212334-000004.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/Trips/20081225%20Maungatapu%20Light%20test/thumbs/20081225-212334-000004.jpg></a>

Oh and a Shinko SR244 at 28psi has more grip than a Pirelli MT21 at 20psi through the Maungatapu even at 10pm in the rain :2guns:

[NordieBoy]

Just checked the rear tyre pressure this morning...

Make that a Shinko SR244 at 15psi has more grip than a Pirelli MT21 at 20psi :o

Thanks to my mad patching skillz :D

[NordieBoy]

Headed off this morning and found a tube at McLean Motorcycles and some talc at the chemist.

I like these Shinko SR244's.
Broke the bead with some wd-40 and my heals.
Talc'd up the new tube, aired it up slightly and bunged it in.
Hardest part was getting the valve stem back in as I only broke the bead on one side.
Lubed up the bead and worked around it with my custom lever and one of the spoons and ended up only using the custom one as it was so much easier and far less chance of catching the tube.

The bead popped at 25psi vs 60psi when I first put the bugger on.

If I was more confident I'd flip the front tyre around as well but I'm not going to push my luck.

Also reinforced the screen onto the bash guards to stop it moving around with some strips of 0.5mm or so alloy strip that I cut out with a pair of scissors :D

Oil and air filter and it's ready for the Dusty :woohoo:

[Transalper]

If I was more confident I'd flip the front tyre around as well but I'm not going to push my luck.
Front tyres are soooo much easier to change than rears... generally.

[warewolf]

I will see if I can borrow my mate's KTM levers for 'show and tell' at the dusty butt BBQ (and maybe the DB itself) as they are the schizzz! They have a lip on the tip to hook the tyre getting it off, and a lip on the underside a little back from the tip to hook the rim getting it on. Ok, got 'em, and they aren't quite like I described. There are no lips on the ends, they are just nicely shaped to cause the same effect.

[NordieBoy]

The ride over to Mangarakau was sweet.
Met HondaV2, HondaV2 Jr, Jatz and Mrs Jatz at the Mot petrol station.
Stopped about every 30 secs on the gravel out to Mangarakau for photos and finally arrived at the Nugget Cafe at about 8pm.
I headed off to the Tuamawiwi the next morning loaded up with christmas prezzies for the family members staying out there and got 12 km when there was a metallic chunkking sound and it wasn't the chain.
I pulled the side cover off the engine and there were small chunks of metal visible :(
I would have been doing about 30kph and in 2nd gear.
I pushed it for over an hour back about 2km along the hills and got a tow the rest of the way.

Bugger :(

More story and some photos to follow when I get back to my computer and am not stuck using this cellphone...

[Transalper]

We wait with anticipation to hear diagnosis.
I wonder if too much farkling has over stressed and thus farlked it.

Very bad time of year for breakdowns.

[buggsubique]

Man, that sucks :no:. One positive is that atleast it didn't happen halfway down the Molesworth in a couple days time. Real interested to hear what you reckon it was - bearing failure? One of them little phillips heads come out of the neutral indicator?

[CrazyFrog]

Nordie, get in touch, my DRZ is avail for you if you want it.
You can join the "sore ass" club with Buggsy and Zerax.

[buggsubique]

hey, it's not what it sounds like...we've both got chicks.

[Ally67]

hey, it's not what it sounds like...we've both got chicks.

:rofl::rofl:

You could ride the XT Nordie, if it's finished @ bazbikes in time.
at least it's colour co-ordinated with your pink jacket :girlfight:

I'm getting real nevous now

[Padmei]

:rofl::rofl:

You could ride the XT Nordie, if it's finished @ bazbikes in time.
at least it's colour co-ordinated with your pink jacket :girlfight:

I'm getting real nevous now

WTF?

What are you going to do just watch? Sorry you are NOT going to let him near that bike:bash:

[warewolf]

hey, it's not what it sounds like...we've both got chicks.Oh, chicks.

Thought you said, cheeks.

[warewolf]

Bugger :(Indeed, how disappointment. :blank:

[Underground]

Nordie, get in touch, my DRZ is avail for you if you want it.
You can join the "sore ass" club with Buggsy and Zerax.

Generous offer crazyfrog :clap: gotta keep nordie rolling we need those pics

[buggsubique]

http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dual-purpose/auction-195494336.htm

[pete376403]

Get this one, you know you want to...
http://www.kiwibiker.co.nz/forums/showthread.php?t=82509

[warewolf]

Snigger (http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dual-purpose/auction-195552174.htm)...

Snigger snigger (http://www.trademe.co.nz/Sports/Cycling/Kids-bikes/Unisex-bikes/auction-195052841.htm) (farkler's dream)

[CrazyFrog]

Snigger (http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dual-purpose/auction-195552174.htm)...

Snigger snigger (http://www.trademe.co.nz/Sports/Cycling/Kids-bikes/Unisex-bikes/auction-195052841.htm) (farkler's dream)

Snigger again, chortle, guffaw, belly laugh out load.......:lol:

[Transalper]

We wait with anticipation to hear diagnosis.
I wonder if too much farkling has over stressed and thus farlked it.

Very bad time of year for breakdowns.


Man, that sucks :no:. One positive is that atleast it didn't happen halfway down the Molesworth in a couple days time. Real interested to hear what you reckon it was - bearing failure?....

:doh: oh the iorny... similar problem maybe and mine did quit on the day and almost exactly half way through the rainbow. ... stock non farkled with engine... 52000km

[NordieBoy]

:doh: oh the iorny... similar problem maybe and mine did quit on the day and almost exactly half way through the rainbow. ... stock non farkled with engine... 52000km

Should have my centre stand in a few days and then the engine'll come out and off to the Nelson Motorcycle Centre for further diagnosis, repair and a metal base gasket while they're at it.

[buggsubique]

Far out, here am I considering a 650 instead of the 400, but theyz all blowin up around me! :Pokey:

Seriously though, Nordie, howd you find the 400 on the ride compared to your 650? bit of a different beast? Good and bad in different areas? I see another 650 has come up on trade me ... kinda considering stepping up to the tractor...

[JATZ]

Far out, here am I considering a 650 instead of the 400, but theyz all blowin up around me! :Pokey:

Seriously though, Nordie, howd you find the 400 on the ride compared to your 650? bit of a different beast? Good and bad in different areas? I see another 650 has come up on trade me ... kinda considering stepping up to the tractor...

I only had a short ride on the dr400 up mt arthur and it was a blast, real fun bike to ride for a short time.felt reeeeeealy small and chuckable. The seat could do with a bit of an upgrade though.
Maybe it was the fact that it wasn't mine made it more fun :devil2:

[NordieBoy]

Seriously though, Nordie, howd you find the 400 on the ride compared to your 650? bit of a different beast? Good and bad in different areas? I see another 650 has come up on trade me ... kinda considering stepping up to the tractor...
Not enough low end stomp for me but a good top end and light and chuckable with a better front end than my 650. I could see how it could be adventurised quite successfully for a shorter person but would need far to much modding for me to get the correct ergos to be comfortable.

The way it was set up was fine for seated riding (apart from the seat) but crap for standing. Needs a way taller seat (seat to pegs increasing) and way taller bars. I could only stand for 20-30s at a time.

It went well though and if I could have more bikes one would be a DRZ400.

[buggsubique]

Yep, agree with all that about the bike. I struggle with the cockpit, but love throwing it round. gotta keep my knees bent standing up. prob should get a set of risers / bigger bend bar... Knees took a hiding after 20 hours on it all cramped up. Good fun bike though.

[CrazyFrog]

The 30mm bar risers I ordered for the DRZ arrived in the post yesterday, too late for the Dusty. I never had problems standing for long-ish periods, just a bit hunched over, hence the purchase of the risers. I do like the chuck-ability of it tho, nice and light, great in the lumpy stuff.

[cave weta]

Not enough low end stomp for me but a good top end and light and chuckable with a better front end than my 650. I could see how it could be adventurised quite successfully for a shorter person but would need far to much modding for me to get the correct ergos to be comfortable.

The way it was set up was fine for seated riding (apart from the seat) but crap for standing. Needs a way taller seat (seat to pegs increasing) and way taller bars. I could only stand for 20-30s at a time.

It went well though and if I could have more bikes one would be a DRZ400.

I had a guy on one of my rides last week with a DRZ400. He was 6'4"
his bike had bar risers that Ive never seen before , they were a 30mm lift and a 60mm step forward. they were on the bike when he bought it and he just loves em.
Also I have to say that my own DRZ400 with the pro circuit pipe and jetting kit is all the bike most people need on the trail. In fact, on the road it will beat my mates CB600R to 140kmh everytime and will also just toutch 167kmh with my chubby little body on it (closed road of course)!:Police:

[Willdat?]

Just bought my first proper bike, a DRZ400 SM, although I can't legally ride it, went for a wee ride around a school yesterday, was grand fun, going to be a long 3 and a bit months till I can go on an actual ride!

Anyone know what the 1000km service is going to cost?

[buggsubique]

1000km service? likely $15 for the oil filter, get a 4L container of 4 stroke oil for about $36, will last two changes. Not sure if you get the valve spaces checked at the 1000km mark...?

I have a 14 meg pdf of the service manual, can burn you a copy if you want. It's all piss easy really for the basic stuff. Ride it over here and we can go through it!

PM me for any further info / queries.:niceone:

Buggs

[Woodman]

[QUOTE=cave weta;1877206]I had a guy on one of my rides last week with a DRZ400. He was 6'4"
his bike had bar risers that Ive never seen before , they were a 30mm lift and a 60mm step forward. they were on the bike when he bought it and he just loves em.
Also I have to say that my own DRZ400 with the pro circuit pipe and jetting kit is all the bike most people need on the trail. In fact, on the road it will beat my mates CB600R to 140kmh everytime and will also just toutch 167kmh with my chubby little body on it (closed road of course)!:Police:[/QUOTE

Bloody hell its faster than me KLR , which um also has a crap seat. But its heavier so better value.

[pete376403]

Bloody hell its faster than me KLR , which um also has a crap seat. But its heavier so better value.

My bro in law has a drz400 and, even with a rattly piston that moves almost as far sideways as up and down, it still hoses my KLR.

But yeah, if you price your bike by weight, the KLR comes out tops for value.
KLRs are currently $57/kilo)
And the '08 has an excellent seat

[talbertnz]

you're a scrap metal man ??? :wari:

[NordieBoy]

Mmmmmmmmmmmmm.....
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090106-074126-000001.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/thumbs/20090106-074126-000001.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090106-074206-000002.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/thumbs/20090106-074206-000002.jpg></a>

[marks]

Also I have to say that my own DRZ400 with the pro circuit pipe and jetting kit is all the bike most people need on the trail. In fact, on the road it will beat my mates CB600R to 140kmh everytime and will also just toutch 167kmh with my chubby little body on it (closed road of course)!:Police:

The DRZ suspension is pretty ordinary - horsepower is no use on the trail if you cant use it


My bro in law has a drz400 and, even with a rattly piston that moves almost as far sideways as up and down, it still hoses my KLR.

My DT230 will totally hose my KLR up to 120-130

but I'd far rather be on my KLR 99.9% of the time



Mmmmmmmmmmmmm.....
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090106-074126-000001.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/thumbs/20090106-074126-000001.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090106-074206-000002.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/thumbs/20090106-074206-000002.jpg></a>

thats feck all use if the thing you attach it to has to be pushed everywhere

[Squiggles]

thats feck all use if the thing you attach it to has to be pushed everywhere

Yep, i reckon he should onsell it :whistle:

[NordieBoy]

The DRZ suspension is pretty ordinary - horsepower is no use on the trail if you cant use it
But still a lot better than the DR and KLR.


thats feck all use if the thing you attach it to has to be pushed everywhere
But it'll help when pulling the engine :D

[Willdat?]

1000km service? likely $15 for the oil filter, get a 4L container of 4 stroke oil for about $36, will last two changes. Not sure if you get the valve spaces checked at the 1000km mark...?


Thanks for the offer!

With a newish bike though do you have to keep the servicing with Suzuki to keep the warranty? It has 24 Months/unlimited kms and was new in May 2008.

Nelson Motorcycle Centre told me $130-150 over the phone which seems a mighty pricey oil change, and to check that nothing has fallen off, the valve spaces don't need to be checked according to the user guide.

[NordieBoy]

Getting it done...

http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090107%20Pulling%20the%20engine/slides/20090107-151108-000026.jpg

And testing the centrestand...

http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090107-154156-000031.jpg
http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090107-154226-000033.jpg
http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090106%20Standing%20on%20its%20own%203%20feet/slides/20090107-154218-000032.jpg

The springs are at the wrong angle to hold the stand up but that can be corrected or just use a bungy on the left side to the passenger peg mount. It's rock solid when it's down though.

[warewolf]

With a newish bike though do you have to keep the servicing with Suzuki to keep the warranty?I understand that legally, no you don't, some searching on here should find a thread linking to the govt consumer website that says so.


Nelson Motorcycle Centre told me $130-150 over the phone which seems a mighty pricey oil change, and to check that nothing has fallen off, the valve spaces don't need to be checked according to the user guide.That sounds like the price for a valve-check service, based on my experience with the DR200 & DR-Z250 over recent years, but maybe the water cooling adds some cost.

I don't mind paying a dealer to do the first service, 'cos I'm happy for an expert to cast their eye over the bike. Might be different if'n I was an expert on the bike in question.

[buggsubique]

Thanks for the offer!

With a newish bike though do you have to keep the servicing with Suzuki to keep the warranty? It has 24 Months/unlimited kms and was new in May 2008.

Nelson Motorcycle Centre told me $130-150 over the phone which seems a mighty pricey oil change, and to check that nothing has fallen off, the valve spaces don't need to be checked according to the user guide.

What Warewolf said. Yep, it is expensive going through a shop and like I said, it is reaaaaallly easy to do yourself - only one way to learn too! Checking valves only requires the fuel tank off and the cam cover, you don't go near the water, so that's pretty easy too, just a couple of things to make sure of to ensure you're doing it right.

[NordieBoy]

Just took 1 hour to double rotate my front tyre and install (successfully) a rimlock :clap:

I'm almost proud.

[NordieBoy]

The 30mm bar risers I ordered for the DRZ arrived in the post yesterday, too late for the Dusty. I never had problems standing for long-ish periods, just a bit hunched over, hence the purchase of the risers. I do like the chuck-ability of it tho, nice and light, great in the lumpy stuff.

Was in the bike shop yesterday and they laughed when I said I liked the DRZ 'cause it's light and chuckable :D
Normally they're hearing about how it's a big heavy pig :laugh:

[buggsubique]

It's all relative, as Einstein would say. Certainly feel like you've been throwing a fat chick around the bedroom all night when you take it into the singletrack though!

[Paladin]

...... Certainly feel like you've been throwing a fat chick around the bedroom all night when you take it into the singletrack though!

Classic!!!!!!! :clap:

[NordieBoy]

Just took 1 hour to double rotate my front tyre and install (successfully) a rimlock :clap:

I'm almost proud.

Rotated the tyre once this time :second:

Sat on the bike for a while making "thump thump" noises and tearing into corners sideways under brakes and powersliding out.
I am a riding god :D

[Padmei]

Jenny is surely one lucky woman:2thumbsup

What now with the bike? Stripped it? waiting for parts? Going to buy a KLR? (I can help you with the screen- I've got one from a Goldwing & am adding a section to the top cos they're not quite tall enough:lol:)

[NordieBoy]

Jenny is surely one lucky woman:2thumbsup

What now with the bike? Stripped it? waiting for parts? Going to buy a KLR? (I can help you with the screen- I've got one from a Goldwing & am adding a section to the top cos they're not quite tall enough:lol:)

You wanting to stay out of the wind whilst standing?

My screen is smashed :(

Shane rotated it around to fit it in a van as one point of the rescue and on the back of the ute on the bypass it flipped back up to vertical in the wind.

It looks like my screen is actually a sports bike screen that's been modified. I'm going to go with a smaller one with a more relaxed angle to direct the wind rather than bash it out of the way.

[NordieBoy]

It's pretty well farked...

The Cylinder head and clutch are fine but that's about it.
They were splitting the cases as I left.

[XF650]

Buggar.
What are the options?

[cooneyr]

Doh that doesn't look good at all! What do you think happened? Almost looks like one of the selector shafts in the gearbox is out of place somehow?

Keen to hear more as you find out.

Cheers R

[marks]

It's pretty well farked...

The Cylinder head and clutch are fine but that's about it.
They were splitting the cases as I left.

fook me thats bad :gob:

so bad I wont even make any KLR references

looks like the 'riding god' will be sitting on the DR making thump thump noises for quite a while

xr250 engine transplant?

[CrazyFrog]

It's pretty well farked...

The Cylinder head and clutch are fine but that's about it.
They were splitting the cases as I left.

Oh God Nordie, you poor bugger! :weep: That looks ....like you said....pretty much farked.
What you gonna do, look for another engine thru the bike wreckers or rebuild it? I know of a LC4 motor (not mine) with low km's you could drop into the DR to make it a fire breathing, bearing crunching beast.
Looks like all I need to do to mine is replace 2 camshaft bearings, a couple of circlips and 2 gaskets, looks like I got off lightly.....
It crunched the outer bearing race when the ball let go, basket and one ball bearing. Snapped two circlips holding the bearing. Cam lobes are mint, and no other crunchy bits to be found.......thank you KTM gods!

[NordieBoy]

I'm leaning toward a tooth breaking and getting stuck between 2 gears and breaking a shaft and the rest cascading from that.

[cooneyr]

....I know of a LC4 motor (not mine) with low km's you could drop into the DR to make it a fire breathing, bearing crunching beast.....

That would be an interesting project given the chain is on the "wrong" side on the 640's :msn-wink:

Cheers R

[NordieBoy]

What you gonna do, look for another engine thru the bike wreckers or rebuild it? I know of a LC4 motor (not mine) with low km's you could drop into the DR to make it a fire breathing, bearing crunching beast.

I'll wait to hear from the shop as a rebuild will be basically a new motor. A $3700 2nd hand '97 complete bike may be an option and transplant the engine. I've also got a 45hp 558cc water cooled engine sitting unused in a Nordwest frame and the drive is on the left...

Decisions desicions...

I get to ride the shop TS185 tomorrow :Punk:
Man that bike makes me feel 8 years old again :D
I learnt to ride on my grandfathers TS125.

[cooneyr]

The other engine option is a Kawa ER500 or KLE500 engine or similar. Bro has just stated looking into a twin that will fit into a XR frame and the 500 motor looks like an option. Seems there is not many compact (pretty much has to be a parallel) twins around. A twin in a lightish bike with decent suspension would be pretty cool. This is exactly what the Webber Rally Twin is.

Cheers R

[Ally67]

Keep your eye out for a DR750/800 motor, I'm sure with yours and Shanes skills you could make it fit

[pete376403]

The ER6n 650 twin is physically smaller than the 500, and has a ton more power.

I think that would also be a nice motor to drop into a KLR frame (not that there is anything wrong with the KLR motor of course)

[Transalper]

Don't know much about the guts of an engine but yep, doesn't look pretty to me.
I await with great anticipation your next update.

My mechanic is out of action for a bit so i'm pushing my bike across the road to use the workshop at my work and PLUG is coming over on Thursday evening where we'll have a bit of a look at it. Dump oil, remove side cases etc, try get an idea what's what.
Heaven forbid it looking like yours.:mellow:

[warewolf]

I'll wait to hear from the shop as a rebuild will be basically a new motor. A $3700 2nd hand '97 complete bike may be an option and transplant the engineBuggery bollocks :crybaby:

A whole 'nother bike means a second set of wheels/gearing for quick mode swaps. Re-tune the second set of forks & shock for motard/street performance??

[Woodman]

The ER6n 650 twin is physically smaller than the 500, and has a ton more power.

I think that would also be a nice motor to drop into a KLR frame (not that there is anything wrong with the KLR motor of course)

No but 10 more hp all over would be nice with the stock gearing you have to admit.

Nordie, make sure if you are rebuilding it make sure you find the cause (not always obvious) and don't just fix the symptom(s). I am sure your guy knows what he is doing but as someone who rebuilt engines for 15 years I,ve seen this happen more times than I care to remember. Mind you looking at the pics another engine would be the go.

What a bugger for you.:argh:

[Transalper]

Well, PLUG and cooneyr called in and did a bit of looking in to things but decided to stick the side cover back on and just remove the engine when they pulled out the attached souvenir from within.

[buggsubique]

How many K's on the engine? That just sucks :weep:.

[Padmei]

Well, PLUG and cooneyr called in and did a bit of looking in to things but decided to stick the side cover back on and just remove the engine when they pulled out the attached souvenir from within.

Was that bit an optonal extra? Kind of looks important I guess. Bad luck:(

[NordieBoy]

It'll be interesting to see if my gear broke in the same place.

[NordieBoy]

Sounds like for peace of mind a 3rd gear replacement every 50,000km would be in order.

NordieBoy - 2001 60,000km
TransAlper - 2001 55,000km

I've asked on AdvRider and TT if anyone who has had a gearbox let go could get me the model year and mileage of the bike.

[Transalper]

How many K's on the engine? That just sucks :weep:.
It's a 2001 DR650 with 54000km on it.
It's been looked after fairly well service wise and although I do not consider it thrashed, it hasn't exactly been nannered either.
It wasn't labouring hard when it actually broke too.

[XF650]

Did either of your bikes have the dreaded 3rd gear "whine", before the clunk bang failure?

[helenoftroy]

Gulp!!mines a 2001 51,000:sick:

[Transalper]

Did either of your bikes have the dreaded 3rd gear "whine", before the clunk, bang failure?Not mine, not that I could hear at least.

[NordieBoy]

Did either of your bikes have the dreaded 3rd gear "whine", before the clunk bang failure?

Nope. No whine.

[NordieBoy]

Gulp!!mines a 2001 51,000:sick:

I'd be inclined to get 3rd replaced and hit the old one with a hammer and see what happens.

I'm off now to have a look at my debris and get some pics of the gear.

[Crisis management]

Thats bad news Nordie & TA (hope yours isn't as bad) if there is anything I can do from up here, second hand engines etc, please ask, I'm more than happy to help.

My 5cents worth tho, just get a second hand engine if possible or it may be better to avoid the cost of a complete rebuild, sell what you have and get another bike. Do your sums before making any decisions.

Iain

[NordieBoy]

<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-112418.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-112418.jpg></a>

This is 3rd gear. All the damage was caused by this beastie...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-112927.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-112927.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-112957.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-112957.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113053.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113053.jpg></a>

This was the bit that went to town on the conrod...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113109.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113109.jpg></a>


How the bits fit together and where they broke...
<a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113300.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113300.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113317.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113317.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113339.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113339.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113356.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113356.jpg></a> <a target=_new href=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/slides/20090116-113409.jpg><img src=http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090113%20Blown%20engine/thumbs/20090116-113409.jpg></a>

[NordieBoy]

Anyone that can keep an eye out for a 2nd hand engine would be much appreciated.

[Transalper]

Sell ya mine, it's a bit 2nd hand.:hug:

[cooneyr]

Bit of info for those with damaged engines. I had a 96 yanky DR650 with a bad third gear whine. Asked on the DR650 Yahoo forum a couple of times about the third gear whine and never got any response. In the end I got the engine stripped down and checked by DAS. They found that the third gears were badly cut for each other i.e. were not an ideal shape for a pair of gears, however there was absolutely no wear on the gears. DAS as part of the inspection replaced two gearbox bearings (not sure which two but were both were shaft bearings not gear bearings), set of rings and heady tidy up (new seals, valves lapped in), oil, filer, spark plugs and gaskets. All up cost was around $1200.

I'm not sure what gears will cost but subject to other damage I'm guessing that $1500 would get TA a pretty long way to getting the bike back on the road. Nordie it looks like you might not be so lucky.

Attached are a couple of pics of TA's engine being removed.

Cheers R

[NordieBoy]

DAS as part of the inspection replaced two gearbox bearings (not sure which two but were both were shaft bearings not gear bearings), set of rings and heady tidy up (new seals, valves lapped in), oil, filer, spark plugs and gaskets. All up cost was around $1200.

I'm not sure what gears will cost but subject to other damage I'm guessing that $1500 would get TA a pretty long way to getting the bike back on the road. Nordie it looks like you might not be so lucky.

The other guy up here in Nelson who had his go got the cases and barrel welded up and everything else replaced. I'd be thinking Transalpers will probably also have that chunck of case missing :(

[NordieBoy]

DR650 3rd gear blowups...

NordieBoy (NZ) 2001 60,000km
Transalper (NZ) 2001 55,000km
Rosscoact (AU) 2004 13,000km
Mardy (US?) 1997 53,000km
TH (NZ) 1999 40,000km
RubberCow80 (AU) 2001 25,000km (2nd gear?)
Philth (AU) 3 bikes <20,000km (2nd gear?)
BikeRooter (AU) 2006 10,200km

I'd probably put the 2nd gear ones as Aussies tanked up on fourecks being confused about this "counting" thing.

I'm starting to think it's 3rd gear itself. The design of it with the thickness of the metal and the selector grooves and the more you use 3rd gear under load.

All the low mileage ones are Aussie with quite possible heavy 3rd gear sand use.

[XF650]

Great research there Fran. I'v been following your survey on AdvRider & Thumpertalk too and it seems you might have uncovered another "doohicky"?
I'm very interested because my 3rd gear whine's, to the extent I try to avoid using that gear where possible.
Obviously the 3rd gear whine & breakage issues are linked (poor machining?), however there doesn't seem to be evidence that the former leads to the latter. When you consider how many DR650's are sold, these issues effect only a very small %. But it's still a lottery.
Interweb search reveals that the 3rd gear 'whine' is still occuring in models as late as 2008, which seems to indicate that the cog quality issue hasn't been fixed?

[warewolf]

I'd probably put the 2nd gear ones as Aussies tanked up on fourecks being confused about this "counting" thing.I wouldn't, at least they can spell Fourex. (Ecks is actually a now-defunct Aussie soft drink manufacturer whose products included "Ecks Beer" which was non-alcoholic :D)

Seriously, if you didn't know, philth is a very experienced motorcyclist, friend of TK (SideTrack magazine) and regular contributor. If he says definitely 2nd gear, I'd not doubt it. If he said he wasn't sure, then ok could be 3rd.

[Woodman]

Great research there Fran. I'v been following your survey on AdvRider & Thumpertalk too and it seems you might have uncovered another "doohicky"?
I'm very interested because my 3rd gear whine's, to the extent I try to avoid using that gear where possible.
Obviously the 3rd gear whine & breakage issues are linked (poor machining?), however there doesn't seem to be evidence that the former leads to the latter. When you consider how many DR650's are sold, these issues effect only a very small %. But it's still a lottery.
Interweb search reveals that the 3rd gear 'whine' is still occuring in models as late as 2008, which seems to indicate that the issue hasn't been fixed?

Is there anyone out there making modified 3rd gears? or is it just a design thing and therefore not particularly modifiable.
And i think KLR owners have a patent on the word doohickey, you DR guys will have to find your own word.

[XF650]

"And i think KLR owners have a patent on the word doohickey, you DR guys will have to find your own word."

Fair enough. I think Nordie & Transalper deserve the right to select an appropiate name.

[buggsubique]

"And i think KLR owners have a patent on the word doohickey, you DR guys will have to find your own word."

Fair enough. I think Nordie & Transalper deserve the right to select an appropiate name.



Fucksicle? pretty much what it's done hasn't it?

[NordieBoy]

Seriously, if you didn't know, philth is a very experienced motorcyclist, friend of TK (SideTrack magazine) and regular contributor. If he says definitely 2nd gear, I'd not doubt it. If he said he wasn't sure, then ok could be 3rd.

His west to (almost) east Aussie crossing report was a good read.
TK's wasn't bad either.

He also said 3 bikes went boom and I know one of them only lost the hardening and didn't destroy the engine - Aussies - You can't trust 'em :D

[NordieBoy]

I'm very interested because my 3rd gear whine's, to the extent I try to avoid using that gear where possible.
Obviously the 3rd gear whine & breakage issues are linked (poor machining?), however there doesn't seem to be evidence that the former leads to the latter. When you consider how many DR650's are sold, these issues effect only a very small %. But it's still a lottery.

I'd never heard it whine but this pic would indicate abnormal wear?

[NordieBoy]

The NSU unit is the DR650 doohicky.

3rd gear is just "an issue" at the moment.
< waves hands > It doesn't exist < /waves hands >

[Woodman]

I'd never heard it whine but this pic would indicate abnormal wear?

What is the wear on the shaft like?

How often do you guys change gear without the clutch? does this do harm?

How often do you guys change your oil?

There are a lot of factors to consider when looking into why things fail, it would be interesting to see if any patterns emerge with the guys that have had this problem and those that have not.

[NordieBoy]

What is the wear on the shaft like?

How often do you guys change gear without the clutch? does this do harm?

How often do you guys change your oil?

There are a lot of factors to consider when looking into why things fail, it would be interesting to see if any patterns emerge with the guys that have had this problem and those that have not.

Always shifting with the clutch.
Bugger all wear on the shaft - Pic 1
Split from base of tooth to edge of spline - Pic 2

[Woodman]

Always shifting with the clutch.
Bugger all wear on the shaft - Pic 1
Split from base of tooth to edge of spline - Pic 2

You ALWAYS shift with the clutch??

Is this normal?
Who else always shifts with the clutch?

[NordieBoy]

You ALWAYS shift with the clutch??

Is this normal?
Who else always shifts with the clutch?

Well I actually shift with my left foot but I use the clutch as well on every change. Even on my XR250 race bike.

I have tried clutchless shifting but my foot dosn't move unless my left fingers move.

[Woodman]

Well I actually shift with my left foot but I use the clutch as well on every change. Even on my XR250 race bike.

I have tried clutchless shifting but my foot dosn't move unless my left fingers move.

I am in the process of changing my clutchless habit mainly cos when I change up into 2nd then throttle off soon after it slips into neutral which can be scary when you expect a bit of engine braking.

But does anyone know if it can cause premature wear, to the dogs etc. BTW I generally only do this on the upshift.

Found advrider and have been following the gearbox saga there . very interesting.

[Transalper]

....How often do you guys change gear without the clutch? does this do harm?

How often do you guys change your oil?.....
99.9% of gear changes I use the clutch.
When done right a clutchless shift is as smooth as using the clutch and many people do it on many different bikes will no heard of ill effect.
When done smoothly I can not see how it could possibly do any harm.

I change my oil and filter together generally around 4500 to 5000km (service book says do oil every 6000km and filter every 12000km) and am use a nice Elf 10w40 semi synth.

[NordieBoy]

Some bikes shift smoothly without the clutch.
CrazyFrogs DRZ is one. I did the occasional clutchless shift when I was videoing and had the camera in my left hand.

[Woodman]

Some bikes shift smoothly without the clutch.
CrazyFrogs DRZ is one. I did the occasional clutchless shift when I was videoing and had the camera in my left hand.

maybe i will continue doing what I do then.
My Focus has handled about 120 ks with a lot of no clutch shifts and its fine, and has never had gearbox oil changed.
Don't really know a lot about gearboxes.

[warewolf]

How often do you guys change gear without the clutch? does this do harm?I would venture to suggest that it is easier to cock up a clutchless shift, and harder on the drivetrain when it happens. Done correctly it's as good as any other method. It can also be a good idea to pre-load the gear lever as per clutchless shifts, even if you use the clutch.

I'm not a big fan of clutchless shifts because I find it takes a distracting amount of concentration to do it well, unless you do it by rote. And it is difficult to do it by rote if you routinely ride different bikes with widely different gear shift and throttle response. Using the clutch is just easier and more reliable.

[Woodman]

I would venture to suggest that it is easier to cock up a clutchless shift, and harder on the drivetrain when it happens. Done correctly it's as good as any other method. It can also be a good idea to pre-load the gear lever as per clutchless shifts, even if you use the clutch.

I'm not a big fan of clutchless shifts because I find it takes a distracting amount of concentration to do it well, unless you do it by rote. And it is difficult to do it by rote if you routinely ride different bikes with widely different gear shift and throttle response. Using the clutch is just easier and more reliable.

Good comments ww. Must do it by rote (habit) cos I always have so it doesn't take any extra concentration.

Nordie a design issue with the 3rd gear could be that it suffers from metal fatigue after a while. 60'000 ks is a lot of use and if it really was designed poorly it would not have lasted that long. Are there many sharp edges/corners on it that are crack risers, e.g. the radius on a crankshaft where the surface of the journal meets the web has to be radiused as much as possible otherwise in time the crank will break.The radius also needs to be machined smoothly to eliminate crack risers too, same reason conrods get polished. Could be similar issues with the gear.
A lot of guys with cars have got their gearbox internals shotpeined to help hold them together.
Might be interesting to get the broken bits and the rest crack tested to see if there any other cracks starting.

[NordieBoy]

From an AdvRider poster...
I may have to investigate this...


I wonder if it is worth replacing 3rd gear every now and again... Is it the drive gear or the driven gear that went?
I might try to find prices, and if it's cheap enough it could be good insurance...

According to alphasports.com the 3rd drive gear appears to have been updated as of 2008 (a different part number: "24231-12D20" -> "24231-12D21") and costs ~$65USD. The 3rd driven gear "24331-14A20" hasn't been updated and costs about $65 as well.
Then there is the cost of new gasket/s and circlip/s.
Part# 09380-25003 Desc 3RD PINION CIRC USD Price 2.31
Part# 11482-32E00 Desc GASKET,CLUTCH C USD Price 15.32
Part# 11483-32E00 Desc GASKET,MAGNETO USD Price 13.44 (just in case)
There doesn't appear to be a gasket for the crankcase itself?
The cylinder gaskets are reusable right?


Anyone 60,000km on their '08 bike yet? :evil

It may look like I'm going over the top, but I just like researching stuff.:D

[NordieBoy]

Also has been pointed out to me that if I was in 2nd gear and the selector fork for 3rd broke then 3rd would possibly mesh whilst still in 2nd... Boom.

[Woodman]

You wouldn't wanna rebuild it with a new 3rd gear and a used selector fork that already may have used up its allotted cycles.

[NordieBoy]

Got another one...

DR650 3rd gear blowups...

NordieBoy (NZ) 2001 60,000km
Transalper (NZ) 2001 55,000km
Rosscoact (AU) 2004 13,000km
Mardy (US?) 1997 53,000km
TH (NZ) 1999 40,000km
RubberCow80 (AU) 2001 25,000km (2nd gear?)
Philth (AU) 3 bikes <20,000km (2nd gear?)
BikeRooter (AU) 2006 10,200km
Madsdad (US) 2005 16,000km

[NordieBoy]

Hmmm...
I wonder how this will go?

Maybe nick the engine/wheels/seat and sell the rest...

[JATZ]

Hmmm...
I wonder how this will go?

Maybe nick the engine/wheels/seat and sell the rest...

You been shopping ?
Or just window shopping
BTW I still got your fat bars, I think I'll stick em on the ct, I'll sort out some folding next time I'm in Nelson

[NordieBoy]

Been shopping :D

[NordieBoy]

Just got informed by the bike shop yesterday that the parts tally came to.....

$7300:shit:

Not including labour...

[warewolf]

Crikey!!!

Hmmm, write-off.

[twotyred]

DR650 3rd gear blowups...

NordieBoy (NZ) 2001 60,000km
Transalper (NZ) 2001 55,000km
Rosscoact (AU) 2004 13,000km
Mardy (US?) 1997 53,000km
TH (NZ) 1999 40,000km
RubberCow80 (AU) 2001 25,000km (2nd gear?)
Philth (AU) 3 bikes <20,000km (2nd gear?)
BikeRooter (AU) 2006 10,200km

I'd probably put the 2nd gear ones as Aussies tanked up on fourecks being confused about this "counting" thing.

I'm starting to think it's 3rd gear itself. The design of it with the thickness of the metal and the selector grooves and the more you use 3rd gear under load.

All the low mileage ones are Aussie with quite possible heavy 3rd gear sand use.

hmmm,that averages out to @ 34000k... with the amount of k's I put on the DR I should be ok for another 25 years or so......:wacko:

[twotyred]

Just got informed by the bike shop yesterday that the parts tally came to.....

$7300:shit:

Not including labour...

:eek:time for an upgrade/update?

[Transalper]

Yep, at that price it's sort of a no brainer.

Mine goes in to the mechanic today.

[cooneyr]

Damn a engine for the price of the whole bike. That sux. Guessing your not even going to talk to the insurance company if you have been shopping already. Probably cost more to write the bike of and buy back the remains??? Whatever the case, good luck!

Keep us posted TA, keen to hear how things go.

Cheers R

[helenoftroy]

Mine goes in to the mechanic today.


Keep us posted TA, keen to hear how things go.
Cheers R
Very keen to hear how things are going TA:calm:

Is Phil doing it?

[warewolf]

Damn a engine for the price of the whole bike.Not surprising when you consider Suzuki sell their whole bikes really, really cheap, then try to claw back some profit with higher margins on parts.

[Transalper]

Is Phil doing it?
No, he is still recovering from shoulder operation.
I tossed a coin in the end and took it to KG Motorcycles in the end.
But it only went in yesterday, I don't know how quick he will be, if I haven't heard anything by Friday I'll pop in for a look.

[buggsubique]

Man I feel for you guys - I had a cambelt go on me once and cost me over $3k to rebuild the motor...dang valve heads rattlin around the cylinder and carving up the head. Always overcautious with engines now, not that you can do much to stop a chunk of steel from flying apart. Here's to quick repairs!:drinkup:

[cooneyr]

Not surprising when you consider Suzuki sell their whole bikes really, really cheap, then try to claw back some profit with higher margins on parts.

Ya win some you loose some. BMW is worse with high bike prices and high parts prices. Guess we had all better ride KTM's aye :msn-wink:

Cheers R

[dino3310]

Ya win some you loose some. BMW is worse with high bike prices and high parts prices. Guess we had all better ride KTM's aye :msn-wink:

Cheers R

the 950 enduro for me please:whistle:

[NordieBoy]

I pick up my donor bike next Sat from Wellywood.
Unfortunatly I'm headed back the same day or I'd have to do a cruz wit da homeys.

[marks]

I pick up my donor bike next Sat from Wellywood.
Unfortunatly I'm headed back the same day or I'd have to do a cruz wit da homeys.

rude bastid :baby:

[warewolf]

Guess we had all better ride KTM's aye :msn-wink:Unfortunately, back in Heytrack's day, the model was the reverse of Suzuki: bikes and parts at realistic prices - non-discounted bikes, but the parts weren't hideously inflated. Since KTM Austria & Australia have taken over, they are heading towards Suzuki's model, curse them.

[cooneyr]

the 950 enduro for me please:whistle:

Get in line dude, I've got the next 950 of the line - yer right!


I pick up my donor bike next Sat from Wellywood.
Unfortunatly I'm headed back the same day or I'd have to do a cruz wit da homeys.

I wouldn't bother with the north island too much. Your better of getting on the boat as fast as possible, getting home, changing the engine over and getting out exploring the Mainland. Just spend 5 days in Hamilton and guess what, there is too many north islanders there. Most seem to think the Mainland is some backwater that isn't even worth visiting. Seems were are doing a bloody good job of telling is like it is :shifty::msn-wink:

Cheers R

[NordieBoy]

rude bastid :baby:

Hell. I'm in Auckland at the moment and have hardly seen any bikes at all. Just got through before the shooting on the motorway though. Is this sort of thing normal here?

[JATZ]

Hell. I'm in Auckland at the moment and have hardly seen any bikes at all. Just got through before the shooting on the motorway though. Is this sort of thing normal here?

Auckland !

you boor bugger

[NordieBoy]

Auckland !

you boor bugger

Where are the hills?
have they sold them to foriegn intrests and shipped them overseas or something?

[JATZ]

Where are the hills?
have they sold them to foriegn intrests and shipped them overseas or something?

They dont have hills, they have bumps and call them "mountains" :lol:

Mt Victoria, Mt Eden, Mt Roskill, Mt Cambria(actually an old quarry in Devonport that used to be a mountain) etc. etc. :yawn:

[Padmei]

They dont have hills, they have bumps and call them "mountains" :lol:

Mt Roskill, :yawn:

Hey thats the bump I was born & bred upon. It was once described by Metro mag as a suburb where "people mowing their backyards look up & marvel at planes carrying people from other suburbs to destinations overseas"

God I miss the drizzzle, traffic, masses of people, shopping malls... All Ive got now are sea views, empty gravel roads 5 mins away, & sunshine... Oh well things can only get better:msn-wink:

[JATZ]

Hey thats the bump I was born & bred upon. It was once described by Metro mag as a suburb where "people mowing their backyards look up & marvel at planes carrying people from other suburbs to destinations overseas"

God I miss the drizzzle, traffic, masses of people, shopping malls... All Ive got now are sea views, empty gravel roads 5 mins away, & sunshine... Oh well things can only get better:msn-wink:


Yup... Exile's a bitch aint it.

Like you I left the "Big Smoke", but I'm learning to cope

[talbertnz]

They dont have hills, they have bumps and call them "mountains" :lol:

Mt Victoria, Mt Eden, Mt Roskill, Mt Cambria(actually an old quarry in Devonport that used to be a mountain) etc. etc. :yawn:


:eek5: There are people living on the south island?????

:wacko: :scratch: You poor things!!!! :eek5: Motueka??? :doobey: :doobey: :doobey:

[warewolf]

Well Nordie grew up here, but are all the rest of us JAFARs?

Just Another Friendly Auckland Refugee!!

[Ally67]

Well Nordie grew up here, but are all the rest of us JAFARs?

Just Another Friendly Auckland Refugee!!

Ahem......
In your case wouldn't that be "just another friendly australian refugee" :whistle:

[NordieBoy]

ahem......
In your case wouldn't that be "just another friendly australian refugee" :whistle:

jafaar :D

[warewolf]

We did used to say to people we were "double jafa's" aucklander & australian. Really took the wind out of their sails.

[NordieBoy]

After having a really nice flight up to Orkland and down again they just had to go and stuff it up by shipping in some turbulance for the last 10mins.

Faaaarrrrk I hate that :sick:

On Sat I'll be going to Wellywood on Sounds Air :(

[Aslan]

Fran - hope the pick up and delivery trip of the new to you DR65O goes well - you did indicate you won't have time to meet up with any us Wellywood adventurers - cheers Aslan

[NordieBoy]

Picking the bike up at 9am and reporting for the ferry at 12:00.

But going by the ferry prices a Wellington ride weekend may not be far off :D

[NordieBoy]

I went for a ride on the other local DR650 that's had the gearbox go and it feels like the counter balancer is a tooth or 2 out. At about 60kph in 3rd it's vibrating quite a bit as though it dosn't want to wind up any more.

[NordieBoy]

Also it made me realise that I was definitely in 2nd gear when mine died.

This makes things confusing....

[NordieBoy]

Picked up the new(ish) bike today (thanks Aslan) and need sleeeeep.

Coupla quick notes though...
1. Noticable 3rd gear whine.
2. He'd bought it lowered and raised it back up. Except the forks are still internally lowered (2.5cm shorter than mine).
3. Don't like the stock seat.
4. Engine runs fine, pulls well and shifts smoothly.
5. Small leaks from one of the valve inspection covers and the screw in the back of the camchain tensioner.
6. Shot front tyre (worn) and a split in the carcass of the TKC80 rear.

I think it'll make a fine organ donor :D

[JATZ]

Sooooo, did ya feel dirty and unfaithfull coming over the Maungatap on it ?

[NordieBoy]

Sooooo, did ya feel dirty and unfaithfull coming over the Maungatap on it ?

Wasn't game to do the Maunga.
The tyres had about 15psi in them and in Picton I put about 30psi in.
The front tyre is shot even by my standards.
Didn't trust the rear with the split carcass.

:whistle:

[JATZ]

Wasn't game to do the Maunga.
The tyres had about 15psi in them and in Picton I put about 30psi in.
The front tyre is shot even by my standards.
Didn't trust the rear with the split carcass.

:whistle:


HA. 15psi thats more than twice what you need :bleh:

thats one ugly tank on the new stead..

[topo]

thats just a regular ol scratch on a mitas!:Pokey:

will see you out on the trail soon nordie.

[NordieBoy]

thats one ugly tank on the new stead..

Yeah. Why do all the bikes I buy have tank covers?
LS400, XR250, DR650, DR650.

[cooneyr]

.....1. Noticable 3rd gear whine.....

97 built, yanky spec DR650 with a 3rd gear whine. That sounds familiar. Good luck with the transplant.

Cheers R

[Crisis management]

97 built, yanky spec DR650 with a 3rd gear whine. That sounds familiar. Good luck with the transplant.

Cheers R

Thats a terrifying combination...remember the sprag clutch on the starter motor drive......

Hope it all goes well with the transplant.

[NordieBoy]

Thats a terrifying combination...remember the sprag clutch on the starter motor drive......

Hope it all goes well with the transplant.

Sprag issues were 98-99 :D

Anyway the torque limiter is one of the bits that survived in my engine.

[warewolf]

Didn't trust the rear with the split carcass.Probably a good call. That's what my Crossengo looked like on the outside, but inside it was a jagged rough-edged tear with bits of the cords poking through. :crazy:

[cooneyr]

Sprag issues were 98-99 :D

Anyway the torque limiter is one of the bits that survived in my engine.

Good call CM. Definitely worth the time to take the LHS cover off when you do a oil change Nordie. Mine had the torque limiting gear but it is right near the change over.

Cheers R

[NordieBoy]

Idea is to run it for a week and change the oil and pull both side covers off and check the NSU and torque limiter.

Remember with my 7" headlight I thought it'd be a couple of weeks after I got it that I'd be able to get it installed and the next day it was done?

Well I was going to ride the new(ish) bike for a couple of weeks to get used to it and then swap the engine over to see what the difference was like.

Ummm...
It's done...

From popping the doner onto the stand...
http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090201%20Engine%20swap/slides/20090201-141029-000014.jpg

To starting it up...
http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090201%20Engine%20swap/slides/20090201-161818-000007.jpg

Was 2hrs 10min, 3 redbulls and a coffee.



WARNING!!!
Anyone contemplating this do not use the seat off the doner bike!
Your retinas will be scared for life.
http://www.photostorage.nelson.geek.nz/sports/motorsport/mybikes/DR650/20090201%20Engine%20swap/slides/20090201-163358-000006.jpg

[JATZ]

Helps to have a good mechanic swing by and give ya a hand.

Test ride tomorrow then ?

[Padmei]

Anyone contemplating this do not use the seat off the doner bike!
Your retinas will be scared for life.


your retinas are gonna have to harden up

[talbertnz]

well done!
curious: did you use your old set up carbie? did it run well on that?

[NordieBoy]

Using my old carb/header/pipe the mid-pipe has a 3cm long hole by the middle mount though.

I also tested it at about 96dB at 3000rpm 1m from the exhaust at 45 degrees.

I only had to wind the idle up on the carb. Tomorrow I'm going to pick up my twin electrode plugs from the dead engine. This one is running the original denso's from '97.

[NordieBoy]

Test ride tomorrow then ?

I think Shane is keen to get out for a ride too :2thumbsup

[NordieBoy]

I also put the 97's OEM bashplate on to see how it goes.

[NordieBoy]

Just got back from a nice slow test run through to Pelorus and back.

The engine has a little less bottom end than mine did but I'll check the valve clearances when I do the 1st oil change and the bike felt a "different" in the front but I think that was the freshly rotated front tyre.

I love my bike :love: it's like putting on an old comfortable pair of boots and going for a walk after borrowing someone elses that are the wrong size.

I need to do some grinding work on the centre stand/side stand interference where the footsies of both touch together.

After riding Shanes TT350 for the last couple of weeks I could really see the benefit of a 45 rear sprocket combined with 14/15/16 fronts.

[Aslan]

Fran - glad you're pleased to be reunited with our regular bike - quick work eh - cheers S

[NordieBoy]

Having a look at the gear cluster today and it seems that 3rd gear is a very hard working gear.
2nd and 4th are freely rotating on the shaft and 3rd is driven.
In 2nd gear 2+3 mesh together sideways, in 3rd gear 3rd is solo, in 4th gear 3+4 mesh sideways.

3rd is under load in 2nd, 3rd and 4th gears.

[talbertnz]

you might be intrested in this (post no 4):
http://www.advrider.com/forums/showthread.php?t=429917

[NordieBoy]

you might be intrested in this (post no 4):
http://www.advrider.com/forums/showthread.php?t=429917

Dad is getting my old spare head to have a play with.
He's going to clean it up, 3 angle valve seat job and taper the 90 deg lip out to the exhaust header.

It's cool. 1 brother is a bike mech and dad does porting jobs :D

Although other than the valve seats I'd be happy having a play with a sanding drum on a dremel in there :Punk:

[NordieBoy]

Just pulled the clutch cover off and checked the NSU.
Only 1 loose screw :sweatdrop


The other one isn't there at all...

:shit:

[warewolf]

Do you feel lucky, punk? Do ya?

[NordieBoy]

Do you feel lucky, punk? Do ya?

I'll just pick the bike up and shake any loose bits towards the back and then...

[NordieBoy]

I'll just pick the bike up and shake any loose bits towards the back and then...

Shane came around with a good telescoping magnet/probe and we found...

Nothing...

Tipped the bike around and over and there were no rattles or anything.

It may have come out with a previous oil change.

I'm getting a magnetic sump bung on monday just in case.

We put a cap screw with studlock in the bottom hole and tightened up the upper one (1/4 turn).

Shane wasn't too worried about it and headed out to French Pass on it with Grace on the back.

[NordieBoy]

Shane and Grace got back from French Pass Sat arvo and I have a shufti at the rev counter telltale... 7,000rpm. Apparantly around the outside of a sportsbike in 3rd gear 2up up the Wangamoas.
I think he had punch marks in his kidneys from Grace.

The exhaust mid-pipe has melted quite a bit more of the rear brake line clip and bit of the brake line with a bit of serious 2up bottoming out through the Maungatapu.

The rear tyre has more damage to it in one day than I'd see in a month.

But it survived!

[NordieBoy]

Yesterday I pulled out the stock 1997 Denso spark plugs and cleaned up and put in my NGK twin electrode jobbies from my old engine.
Also checked the valve clearances and the intake were spot on at 0.1mm and the exhaust were a bit tight at about 0.1mm so I adjusted to 0.2mm.
A bit more tappety but after warming up and getting some oil flowing through the head they quietened down.

Headed off out to Atawhai on a chocolate mission and met up with Padmei so we headed up the caretakers up the dam instead.

I rode the mighty Gonzo back...

If you duck down behind the screen it's as though you're riding stoned :D Not quite optically correct...
But neither are the mirrors. Which of the 3 or 4 cars in the right mirror should I be worrying about?

Nice seat.
Squats a bit under acceleration - spring rate?
Smooth power delivery. You're not going to kill yourself accidentally giving it a handfull.
Not enough room for my knees. Very wide tank when standing but still slimmer than the DR Big :D
Loved the highway bars/engine protectors.

The biggest problem for me was the feeling of the front end being "hidden" behind all that fairing. If you were used to it and had confidence in your front tyre it'd be no problem at all and on the seal the fairing proved it's worth but I'm so used to seeing where the front is pointing that it was weird.
Even swapping between my Nordwests was the same with one having the stock non-moving headlight/dash and the other a naked style. Both felt so different even though they were otherwise identical.

I can see why that guy in the States has removed all the fairing on his "adventurised" one. Hidden underneath it is quite a nice bike.

[Woodman]

Was working in Nelson today and on my commute the only 3 bikes I saw going the other way were KLR's.
The universe is ok.

[NordieBoy]

Was working in Nelson today and on my commute the only 3 bikes I saw going the other way were KLR's.
The universe is ok.

It's the vibration. There was only one of them :D

Saw Warewolf coming back down from the Maunga today too.

[Padmei]

Yep the DR is a great bike. It had heaps of grunt, felt lighter & more controllable with the body position seemingly right over the front wheel. The burbling pipe has a great note too. I could ride it all day just to hear the exhaust.

I would like to ride some other KLRs to compare suspension. Perfomancewise it has enough to keep me happy. I enjoy riding behind the screen :love:- I find the wind in my eyes annoying.

[pete376403]

Have you got the tall screen or the standard one?

I can't look through the standard screen unless lying on the tank. As far as seeing the front wheel goes, I can see it ok when standing. When sitting I trust it to be in the right place, doing the right things

[NordieBoy]

When sitting I trust it to be in the right place, doing the right things

Ahhh...
You're one of those other KLR owners. One with actual tread on his front tyre :chase:

[NordieBoy]

Have you got the tall screen or the standard one?

He's got a (very) home-made tall screen which actually works. Especially if you're shorter than me. I copped the wind in the middle of the forehead.

[Woodman]

Yep the DR is a great bike. It had heaps of grunt, felt lighter & more controllable with the body position seemingly right over the front wheel. The burbling pipe has a great note too. I could ride it all day just to hear the exhaust.

I would like to ride some other KLRs to compare suspension. Perfomancewise it has enough to keep me happy. I enjoy riding behind the screen :love:- I find the wind in my eyes annoying.

Dunno if its much of a comparison, but you can have a go on mine, it may be somewhere between yours and a DR except for horsepower:(. I have my suspension as hard as it will go with extra springs in front , and it is still too soft especially on the rear.
Have forgotten what its like to ride a light bike, and I agree Nordies pipe does sound good.
BTW I highly recommend a good bash guard, mine paid for itself coming back over the maunga last weekend. If it wasn't there I would no longer have a waterpump at best. Bashplate is now a completely different shape.

[Padmei]

He's got a (very) home-made tall screen which actually works. Especially if you're shorter than me. I copped the wind in the middle of the forehead.


Looks like a fulldresser Harley but it's made by me for me.;) I would have gone taller but that's all the vyvax they had:weep:

I like the way this thread is becoming a KLR thread - gonna get a few DR boys hot under the collar:angry2:

Haven't had a problem YET with the bashplate & its seen a lot of ...er... top of stuff.

[marks]

Ahhh...
You're one of those other KLR owners. One with actual tread on his front tyre :chase:

I've never seen Pete ride his KLR with any tread on the front tire - or the back for that matter.....

And Nordies pipe is way too quiet

[warewolf]

Saw Warewolf coming back down from the Maunga today too.Oh no you didn't! :eek: Closest I got was cnr Nile & Tasman Sts tonight for a couple of beverages at the Prince Albert.

Is it just me who cringes every time the name of that pub (http://en.wikipedia.org/wiki/Prince_Albert_piercing) is mentioned?? :blank:

[NordieBoy]

Oh no you didn't! :eek: Closest I got was cnr Nile & Tasman Sts tonight for a couple of beverages at the Prince Albert.
Saw the back end of an orange KTM thumper go past when I was up at a job 100m before the gravel starts.


Is it just me who cringes every time the name of that pub (http://en.wikipedia.org/wiki/Prince_Albert_piercing) is mentioned?? :blank:
May be one of the reasons they renamed it to "The Fern Lodge".

[warewolf]

The Fern Lodge is the accommodation section, the pub is still the PA?

[MXNUT]

And Nordies pipe is way too quiet


You wont mind the bark from the rear of my DRZ this weekend then Marks :whistle:

[NordieBoy]

And Nordies pipe is way too quiet

Compared to a Jardine you can stick your whole arm up to clean carbon deposits out!

[pete376403]

I've never seen Pete ride his KLR with any tread on the front tire - or the back for that matter.....

If the Southern Coast ride is still on this weekend (I'm having visions of *that* shingle slip with a few wild rivers raging down it) I will have tyres with KNOBS, not tread, fitted.

[NordieBoy]

Looks like the guy I got my DR from is selling his replacement DR now.

http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dual-purpose/auction-203027292.htm

[Oscar]

Looks like the guy I got my DR from is selling his replacement DR now.

http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dual-purpose/auction-203027292.htm

I see the new price is up to $9,100 - still far and away best value for money for a big traillie.

[NordieBoy]

Just testing Flickr's embedded photos...

<table><tr><td><script type="text/javascript" src="http://www.flickr.com/badge_code_v2.gne?show_name=1&count=5&display=latest&size=m&layout=h&source=user&user=7315641%40N06"></script></td></tr></table>

[Transalper]

Got to watch some of those file hosting places, if no one looks at your photos for a few months with some services they delete your photos. Then we go to the likes of ADV rider forum where everyone uses embedded pictures in their trip reports and the old reports all have photo bucket type icons saying how the picture is no longer available.
Bugger, now I'll never know what the where ever or what ever it was looks/looked like. :no:

[Padmei]

Got to watch some of those file hosting places, if no one looks at your photos for a few months with some services they delete your photos. Then we go to the likes of ADV rider forum where everyone uses embedded pictures in their trip reports and the old reports all have photo bucket type icons saying how the picture is no longer available.
Bugger, now I'll never know what the where ever or what ever it was looks/looked like. :no:

Ah I wondered what happened there. What's the best solution - a hosting place that you pay for?

Nordie how do you embed photos in KB posts? Is it a secret? It ceertainly would make reading posts quicker.

[NordieBoy]

Got to watch some of those file hosting places, if no one looks at your photos for a few months with some services they delete your photos. Then we go to the likes of ADV rider forum where everyone uses embedded pictures in their trip reports and the old reports all have photo bucket type icons saying how the picture is no longer available.
Bugger, now I'll never know what the where ever or what ever it was looks/looked like. :no:

I went into flickr not expecting much but found I already had an account and it had photos from the 2007 DB1K in it.

This little test is e-mailing a pic from my cellphone straight to flickr and it should update in that pic above automatically and show the last 5 pics.
May not be useful but fun 'till it gets boring :D

[NordieBoy]

Ah I wondered what happened there. What's the best solution - a hosting place that you pay for?

Nordie how do you embed photos in KB posts? Is it a secret? It ceertainly would make reading posts quicker.

Just the same as for other sites.
You need a host.
I usually use my own one in the states where I pay $15 a month for 5Gb of storage.

[Padmei]

http://i710.photobucket.com/albums/ww103/padmei_crayfish/DSC01403-2.jpg

ten characters

[marks]

http://i710.photobucket.com/albums/ww103/padmei_crayfish/DSC01403-2.jpg

ten characters

were dat?????

[Padmei]

Sorry Nordie for crashing your thread. I was trying to embed an image like I can in adv rider however can't do it here.

Marks that photos from Port Underwood during xmas.

[Aslan]

http://i710.photobucket.com/albums/ww103/padmei_crayfish/DSC01403-2.jpg

ten characters

Damn fine looking fellow Padmei! (beaut looking KLR too) :soon:

[NordieBoy]

Yep. That's the way to do it.

Your Sony is also underexposing by 2/3 of a stop but don't let that worry you.

:yes:

[NordieBoy]

Cool. It's automatically added the last photo...
<table><tr><td><script type="text/javascript" src="http://www.flickr.com/badge_code_v2.gne?show_name=1&count=5&display=latest&size=m&layout=h&source=user&user=7315641%40N06"></script></td></tr></table>