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The DR900 - DR650 Big Bore Stroker buildup

I drove up to Seattle to pick up a 2007 model for the motor transplant.

Ah...! It's together and running. Starts and idles just like a stock bike. Ran it down the street and back - throttle response is amazing, almost brutal.
Feels like it only takes 2 thumps to loft the front wheel in second or third. First gear just spins the tire when you try to do a wheely!

> he he he he har de har ho ho ha ha yuk yuk yuk
> giggle snicker ho ho ho gasp
> wheeze chuckle ha ha he he snorfle snort har de har
> ho ho ha he he he yuk yuk
> he he he he har de har ho ho ha ha yuk yuk yuk
> giggle snicker ho ho ho gasp
> wheeze chuckle ha ha he he snorfle snort har de har
> ho ho ha he he he yuk yuk
> har de har ho ho ha ha yuk yuk yuk giggle snicker ho
> ho ho gasp wheeze
> chuckle ha ha he he snorfle snort har de har ho ho
> ha he he he yuk yuk he he
> har de har ho ho ha he he
> he yuk yuk he he he he har de har ho ho ha ha yuk
> yuk yuk giggle ho ho ho
> gasp wheeze har de har ho ho ha he he he yuk yuk he
> he he he har de har ho ho
> ha ha yuk yuk yuk giggle snicker ho ho ho gasp
> wheeze chuckle ha ha he he
> snorfle snort har de har ho ho ha he he he yuk yuk
> he he he he har de har ho
> ho ha ha yuk yuk yuk giggle
>
> ahhhhhhhh

:crazy: Just got back from a 40 mile break-in romp in the hills on the DR900. What a hoot!

 

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I've made a little bit of progress. I re-valved the shock and added a 7.5 spring, flipped the spring seat and installed the shock in the lowered position. The forks got Race Tech Cartridge Emulators and .55 springs and were assembled in the lowered configuration. I also added lowering links and slid the fork tubes up in the clamps. It's going to be a bit of a low rider to help keep the front end down.

I'm converting the bike over to yellow plastic. Got a Polysport front SM fender Clarke tank and OEM headlight mask. Still waiting on yellow side panels and my plan is to hack the tail end of the subframe and graft on a rear fender from a DRZ400. It will get a ProCycle seat kit but in the mean time I had this yellow seat sitting upstairs so I figured I'd put that on until I get a proper seat put together.

Got some wheels built. I was originally thinking to run the stock rear with a 18" on the front but I already had a 3.5x17 SM front wheel that needed the hub swapped and I also had a left over 4.25x17 rear rim and spokes. So that made it a no-brainer to set it up with a supermoto wheel set.

Took it out for another spin with the SM wheels on it. Third gear throttle wheelies are do-able. Second gear wheelies are ridiculously easy. First gear wheelies actually take a little bit of technique because if you snap the throttle open too quickly it just spins the tire instead!

 

Because the 900 is 'double lowered' I had to modify the side stand. I chopped a couple inches out and cut a piece of smaller tube to splice it back together.

 

This bike is my chance to try something I've been kicking around for a while - swapping the droopy stock rear fender for a more modern 'sporty' looking DRZ400 fender. I have a take off blue DRZ fender left over from when we converted Mrs. ProCycle's DRZ400 to all black plastic. I'll use it for modeling. Once I have made the old blue one fit I'll modify a new yellow DRZ fender to match. The DRZ fender has the same angled edge where it meets the side panels. That's a good thing for starting out. The stock subframe and fender supports aren't even close to working so I'll be doing plenty of cutting and welding.

I cut the back loop off the subframe. The bridges the support the stock fender were too tall for the DRZ fender so they were eliminated.
The DRZ fender tapers at a tighter angle so I notched the remaining frame tubes and angled then inward.

Subframe mods done.

 

The shorter rear fender made the muffler look way too long so I took 5" out of the length of the muffler body.

 

This whole rear end mod took a lot more time and work than I first expected. It's finally looking about like I imagined and I'm ready to trim the new yellow fender based on the mods to the blue one.

Gettin' there. I have a handful of details still needing to be sorted out.

More to come...

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