1997 DR650 Engine Out Frame Stripped Rebuild
The dash panel is made from silver fiberglas/carbon composite sheet. The frame that holds the VAPOR and supports the dash panels is welded aluminum, then powdercoated. The lights on the VAPOR are left and right turn signals, neutral light and high beam light. On the right side of the dash is a 12v power plug fo the GPS, a Powerlet cig lighter outlet and the small LED is a digital charge indicator tha monitors battery voltage. On the left of the dash are two switches for low beam and LED running lights and below the outlets and controls for the HEATROLLER heated gear controller.
Boot guards are fabricated from 3/32 aluminum with 3/4 inch holes. Both sides are fastened with well nuts into the frame and flathead SS screws. The exhaust guard is also 3/32 aluminum rolled and welded.Yellow wiring loom is Kevlar.
Rack is 3/8 IPS welded and powdercoated. V ertical supports go through the f old tailender to the teo tabs on the frame. Carbon insert where the old tailight went.
YZ Sportbike LED tailight/brakelight/turn signal combo. Also has a license plate light as well. Exhaust is FMF Q4. License bracket id fabricated aluminum. Rack is custome 3/8 IPS welded and powdercoated.
Footpegs are PIVOTPEGS. These are surprisingly comfortable and definitely improve control for shifting and brake.
Agrisupply tube with aircraft SS bracket.
LED running lights from ProCycle with fabricated 1/4" aluminum mounts that use the lower fork tube clamp bolts. The steel ones that are sold vibrate badly. Cut down and reversed CR250 fender protects engine without blocking the cooler.
AMP side case and oil filter covers
Britannia Composites fairing mounted to forks. The are Halogen lights
ZETA handguards with aluminum mounting bars. The handguards and the small LED lights on the fairing are the turn signals
Additional LED turn signal on front fender
Yellow tank trim
Brittania Composites windscreen. Adjustable up and down
Dash is a fabricated aluminum frame located on brackets on the fairing. The black aluminum frame also holds the VAPOR computer. There are two panels, left and right fabricated from 1/16" carbon plate that hold the switches, etc, The left side has two switches for the low beam and the LED running lights. Also has two rheostats and outlets for the HEATROLLER heated clothing plugs. The right side has a PowerLET outlet and a 12v smaller plug for the GPS. The small LED is a Custom Dynamics voltage monitor.
The VAPOR is set up with LEFT and RIGHT turn signal lights, hi beam light and neutral light. Stock ignition switch but the other indicator lights have been removed. GPS is a Magellan CrossOver.
Procycle oversize disc with SS brake lines front and rear. Smaller cable is speed sensor from VAPOR. Front suspension is .50 Eibach springs with Race Tech Emulators (lowered)
Custom fabricated engine guards, then powdercoated. Complete FMF Exhaust (polished) ProCycle. Head mildly ported, 5 angle valve job, 10-1 piston, milled head. Airbox opened. Engine temp (at the plug) is from 285-310F.
Bar extenders so I can use stock control levers
Scotts damper weld on tower. If you ride in sand you need one of these.
Front mount for Agrisupply cannister
Stick on reflector on tool cannister
TKC-80 tires. We have them on our XR-400 and I think they are one of the best dual sport tires.
Fairing is from Brittania Composites. I think Ian is back in production for the DR. Mine is mounted to the forks so it turns with the forks. Paint work for the tank and fairing is by SuperBike in Poway, CA http://www.britanniacomposites.com/.
Bars are KAWI high bend 7/8" ProTaper
Cogent rear shock (lowered)
Added grease fittings to brake lever and swing arm pivots
Right side frame guard
RSW fork brace with neoprene boots and Stainless steel band clamp. If you do this you should use some GOOP or SealAll to mounts the boots. While some may feel that a fork brace is not neccessary for the DR, I think it makes a difference. We've had one on our XR for quite a while and the front end just feels more secure. Go figure. We are not racers but ride in all sorts of terrain.
This is the container from Agrisupply with an aircraft clamp on one end and another curved aluminum bracket on the front along with the existing plastic bracket. Tail light/turn signal combo is a YZR LED sportbike unit
Modified kick stand. 2 inches removed and then replaced with a welded in 3/4" grade 8 bolt. Easily adjustable for extra weight
Right side engine guard fabricated from 3/8 IPS and then powdercoated. The skid plate is a Moose unit but with 5 inches welded onto the rear for better mounting and coverage. The stock rear mounts for the Moose plate looked like they could punch into the case. This plate was probably not the best choice due to the modifications I had to do to it. I think there are better ones out there.