"A Bird in the Hand" take 2. DR650 Deadtail Bobber

Hurco550

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So, a while back I started on an xr600 based hardtail bobber. After thoroughly looking over the frame and power plant, I decided to go a bit of a different direction. The xr600 threw up a few challenges that wasn't "worth it" to me to work past towards the end goal. The xr is a dry sump motor, oil in frame which could have been remedied with an oil bag, BUT I was planning to use the stock main frame. That moved me to the next issue of the rake angle being to steep, which would be harder than usual to change, due to the oil tank being in the backbone. Then, on top of that, I had to source and fiddle with dual carbs.

So enters the 1996 to present DR650 lump. It was chosen for (almost) all the reasons I didn't want to use the xr600 lump.

Pros:
- Still a big bore thumper
- Wet sump motor
- Single Carb
- Large amounts of aftermarket

Cons:
-Electric start only with no ability to add a kicker

I was on the search for a while when Mr.E sent me a link to a DR650 engine for sale "over the mountain" from him in North Carolina. I struck a deal with the seller and E delivered it and a few other DR650 parts to me at Mid Ohio. The story goes that the bike lost spark and so the seller parted it out. I found another guy locally that had a DR650 that lost 3rd gear and so he was parting that bike out. I purchased a boat load of parts off of him, but most importantly a complete ignition, wire harness and c.d.i unit.

Also included was pretty much the entire engine minus the guts and cases (i.e. head, cylinder and case covers) which will come into play in a future post.

The plan is simple, A bare bones, no frills thumper powered hard tail bobber with a short rake, Shouldered spoked 18/19 rims on an xs rear hub and a 2ls Titan front drum. And as the title states, I want to use as many bits that I have laying around as possible to finish this bike.

I will be building the frame from scratch, using a titled KZ550 ltd neck tube that I've got kicking around. The plan right now is also to build a set of girder forks from scratch. I spent a few years building custom roll cages for pulling tractors and one Baja truck. I'm thinking this will be a good way to knock the rust off and hone my skills back in on tubing fabrication and welding.

I've had this frame jig built for a while now, and I'm excited to try to use it to build a complete frame.











And below is a picture of my inspiration bike. I love so much about it. Low and Lean with a short rake, minimal and a high tunnel wassel tank. It even has (pretty much) the same wheel combo I plan to run. If I can hit the proportions of this bike, ill be happy.



Anyways, cheers and enjoy another stupid project from Hurcos (new) garage.
 

Hurco550

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Welcome aboard Mike!

One of the first things that I figured out after hefting the complete spare lump around the shop, is that it will be a HEAVY endeavor to build a frame around it while lifting it in and out of the jig. In my first post, I mentioned getting a spare engine minus the cases and guts. I found a guy on facebook who sent me a bare set of cases on the cheap. One of them had met a rock in an unsavory fashion and left a hole in it, but its fine with me, since I am just building a completely hollow mockup motor.

I got most of the gunk knocked off the cases last night, and then I turned a faux countershaft on the southbend lathe. Its dimensionally offset the same as the stock motor so that I will be able to set up my rear wheel/axle correctly without having to put the complete motor in until final assembly. Once I get the rest of the parts dug out, I will put the rest of the hollow motor together and start bending tubing.
 

ridesolo

You only bear responsibility for your own actions
Lookin' good, Levi. Don't dispose of that mock-up motor, it could come in handy in other endeavors. (You know what I'm talkin' 'bout. But we couldn't/shouldn't/wouldn't turn a Honaki into a Honuzaki, right? Right?)
 

Hurco550

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ridesolo said:
Lookin' good, Levi. Don't dispose of that mock-up motor, it could come in handy in other endeavors. (You know what I'm talkin' 'bout. But we couldn't/shouldn't/wouldn't turn a Honaki into a Honuzaki, right? Right?)
oh believe me, once I get the mockup motor done, you know im gonna see if it slides in that frame ;) we need to dr650 everything haha
 

Hurco550

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canyoncarver said:
So it IS true, all the cool kids are doing it. :)
Ha, well I mean you do have a Norton.... JK, if you chop that thing up I will never forgive you

irk miller said:
It's about damn time. 8)
Hey man, ive started like 5 different ones at this point, doesn't that count for something?

cbrianroll said:
Cool man....watching.
Thanks man!
 

canyoncarver

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Hurco550 said:
Ha, well I mean you do have a Norton.... JK, if you chop that thing up I will never forgive you
You have nothing to worry about, keep calm and fab on.
 

Hurco550

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Re: "A Bird in the Hand" take 2. DR650 Deadtail Bobber

Glad to have y'all!

Got my mock-up motor put together last night. I don't have exact weights (I don't own a scale, I don't need that kind of negativity in my life) but this is going to be much much easier to build around than a complete motor. I guessing it's right at 1/3 the weight of the complete lump. Its about as empty as possible, less disassembling they head and rocker boxes.



 

ridesolo

You only bear responsibility for your own actions
Nice! You'll have to build a dedicated shelf on the wall for it so it has an appropriate, decorative home when it isn't in use. Potential wall art for sure!
 

Hurco550

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Re: "A Bird in the Hand" take 2. DR650 Deadtail Bobber

ridesolo said:
Nice! You'll have to build a dedicated shelf on the wall for it so it has an appropriate, decorative home when it isn't in use. Potential wall art for sure!
haha I've already got an end table dedicated for it in the basement ;)

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Hurco550

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Re: "A Bird in the Hand" take 2. DR650 Deadtail Bobber

A very well documented performance upgrade for the dr650 motors is an fcr39mx carburetor. They came stock on the carb model Yamaha yfz450 atv's, and a guy that goes by mx_rob on some of the other forums has a really great write-up on how to set these up for the dr650 motors. I bought and modified one a couple years back for my 06 DR650 and have been so impressed by the performance that I decided that this needs one too. I have had generally good luck with facebook marketplace up until I tried to buy one of these carbs off of there. Apparently being a generally sketchy person / meth head is a pre requisite for selling one on there. I'm in the middle of a papal dispute on one right now who sent me a false tracking number and another guy who initiated a trade deal on an old mini bike frame, flaked last minute. I gave up on trying to save a few bucks on Facebook and found this one and made an offer on eBay. It'll be shipped to my door for about $30 more than the papal dispute facebook carb. Hindsight is 20 20 I guess.

Anyways, ill have this carb mounted as well, for another piece to build the frame astound, as it is a pretty large piece of kit.



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pidjones

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Re: "A Bird in the Hand" take 2. DR650 Deadtail Bobber

>>>Apparently being a generally sketchy person / meth head is a pre requisite for selling one on there.<<<
My observance, also. And, why are so many things posted for someone else? One thing that I've learned about bikes for sale on it, is that if they won't haul the bike out into the sunlight, wash it off, and take some decent (even if cell phone) photos, it is actually worse than the dim photos of the bike between two tillers with a matress on top reveal.
 

Hurco550

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Re: &quot;A Bird in the Hand&quot; take 2. DR650 Deadtail Bobber

It is a strange thing, but to be honest this is the first real bad luck I've had with it. My tw200 came from Facebook marketplace, as did my xr500, as did the engine for this build etc etc. Seems as though the smaller the part gets, the harder it is to find a reasonable person to buy it from.

I also passed on a couple of these carbs that people wanted $250+ for because "that's what they sell for on eBay". When I sent them active buy it now listings for sub $150, they got all torqued off at me. Oh well.

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SONICJK

Reminds me of...me No, I'm sure of it. I hate him
Re: &quot;A Bird in the Hand&quot; take 2. DR650 Deadtail Bobber

Hurco550 said:
It is a strange thing, but to be honest this is the first real bad luck I've had with it. My tw200 came from Facebook marketplace, as did my xr500, as did the engine for this build etc etc. Seems as though the smaller the part gets, the harder it is to find a reasonable person to buy it from.

I also passed on a couple of these carbs that people wanted $250+ for because "that's what they sell for on eBay". When I sent them active buy it now listings for sub $150, they got all torqued off at me. Oh well.

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I find the same thing. It makes sense, the smaller the item the smaller the profit. If someone really needs to sell a pair of stock handlebars and is going to go through all the trouble of setting up a sale etc for 10 bucks they must really need it (for meth lol)

I've got a DR for sale on CL at the moment and it's a PITA just with all the damn people asking me questions all day. It's cheap, buy it or dont!




is this thing done yet?
 

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