Eddieb's DR build thread.

[NordieBoy]

Sounds like the Scottie vacuum isn't working.
Quite ready to lighten the Intiminators action with a shim adjustment.

[Eddieb]

A few niggling health issues mean I haven't got any riding in since the South Island Invasion except one trip to Box'a'bits house, however I've still been working on a few things on the side.

One of those was obtaining a set of 43mm 2002 DRZ250 cartridge forks with adjustable damping and rebound. The DRZ250 forks slide straight into the 650 clamps and use the same axle, spacers, speedo drive and caliper as the 650, but requires either the 250 wheel and disc, or a brake caliper adapter bracket for the 650 wheel as the 250 uses a 250mm disc and the 650 290mm, also the disc offset is approx 1-2mm different.

So a visit to my local friendly engineer resulted in this...



The forks still need respringing but I've bolted them in to test fit everything before I went too far.

[dino3310]

nice one bro looks good

[pete376403]

Suspension modifications, steering modifications and brake modifications - engineers certification would seem to be a requirement if you want to *legally* use this on the road.
Either you'll need a friendly WOF issuer or it looks standard enough for the testers at VTNZ, etc not to notice.

Will watch with interest 'cos I'd like to do similar with the KLR (YZF USD front end).

[Eddieb]

Suspension modifications, steering modifications and brake modifications - engineers certification would seem to be a requirement if you want to *legally* use this on the road.
Either you'll need a friendly WOF issuer or it looks standard enough for the testers at VTNZ, etc not to notice.

Will watch with interest 'cos I'd like to do similar with the KLR (YZF USD front end).

I did the popular RF900 caliper upgrade to my GS PD which involves a bracket on only one of the caliper bolts to space the caliper out, I did 3 WOF's on that without issue.


Box'a'bits doesn't seem to have had any problems with his YZ upgrade so far.

As it happens the mechanic from my local dealer where I usually get my wof's done walked into the engineers as I was picking up the forks/wheel with the new bracket fitted so he knows it's there.

I don't use VTNZ anymore, most of the ones near me don't have anyone that can do bikes, and the one that does will never see my business again after failing a bike but not being able to explain in plain english why, and then getting really short with me because I insisted he explained it in terms I understood so that I could get it dealt with, and he couldn't without using engineering terms I wasn't familiar with.

If it becomes an issue I have all the original parts and none of those have been altered, it would take less than 30 minutes to refit the stock forks again. I also have a RMX250 front wheel with a 250mm disc. I'm yet to offer that up but it should slot in to the DRZ forks and caliper without the bracket as long as the disc offset is the same as the DRZ.

[Woodman]

Suspension modifications, steering modifications and brake modifications - engineers certification would seem to be a requirement if you want to *legally* use this on the road.
Either you'll need a friendly WOF issuer or it looks standard enough for the testers at VTNZ, etc not to notice.

Will watch with interest 'cos I'd like to do similar with the KLR (YZF USD front end).

Was wondering that myself cos semi considering doing the same. Cars don't need recertification when replacing the shock absorbers so I don't really see an issue, but I would keep my original front end just in case.

[NordieBoy]

As long as you're going the same or stronger then there shouldn't be an issue.

It's like re-powering a bike. No issue unless the new engine is more powerful than the original.

[Eddieb]

So I finally got around to fitting my FCR carb today, are they all really nosy? I haven't got the airbox on yet but have the intake pipe and the clattering is so loud it almost drowns out the exhaust.

Also got my new 50mm bar riser installed though it required a lot of cable rerouting, my attempt at putting new springs into the DRZ 250 forks failed as the fork caps would only unscrew about 1/3 - 1/2 of the way then there would be an audible and feelable click on each rotation and it wouldn't undo any further. Not sure if/what I was doing wrong.

[NordieBoy]

So I finally got around to fitting my FCR carb today, are they all really nosy? I haven't got the airbox on yet but have the intake pipe and the clattering is so loud it almost drowns out the exhaust.

Not nosy at all, not noisy either...

Although they do have a cool whistle to them on throttle close.
It's the blow off valve for the FCR's turbo unit.

[Eddieb]

Not nosy at all, not noisy either...

Although they do have a cool whistle to them on throttle close.
It's the blow off valve for the FCR's turbo unit.

mmm, wonder whats going on with mine then. I'll try to take a video as it's REALLY clattery.

Also it revs pretty freely but doesn't drop down to idle again straight away, there's a few seconds delay. I couldn't get the return cable set up with enough tension for it to pull the throttle fully closed so it's relying on the spring only. I also had to extend the adjuster for the pull cable near the bars to almost full extension to get enough tension in that cable.

[Eddieb]

The best example of the noise is as I walk up to the bike in the first few seconds. The motor is cold but the revs increase significantly when the choke is turned off.

[NordieBoy]

mmm, wonder whats going on with mine then. I'll try to take a video as it's REALLY clattery.

Also it revs pretty freely but doesn't drop down to idle again straight away, there's a few seconds delay. I couldn't get the return cable set up with enough tension for it to pull the throttle fully closed so it's relying on the spring only. I also had to extend the adjuster for the pull cable near the bars to almost full extension to get enough tension in that cable.

The return cable has to be loose. Any tension at all and it'll be slow to return.
It's only there for emergency situations.

[NordieBoy]

The best example of the noise is as I walk up to the bike in the first few seconds. The motor is cold but the revs increase significantly when the choke is turned off.

I think that'd quiet down quite a bit once the airbox is connected.

[Magnum Noel]

I think that'd quiet down quite a bit once the airbox is connected.

I agree sounds normal to me. Actually bike sounds sweeeet

[Eddieb]

Guess I'll have to bolt it up again and take it out for a run and see how it goes.