Owenski's Drz Inbetweener build.

[Owenski]

So after a year of ownership I've decided now would be a great time to get the ball rolling on the hyper-drz build. Unfortunately this thread isn’t for that bike, this thread is to document the one I’m building to use for the period I spend converting my current daily drz one into the hypertard if you're following this on the drz forum then you'll only see duplicate info by reading further.

The bike in this thread will be going up for sale once the hyper is completed and as such I’m hoping to use this thread to document its creation.

I had chance yesterday to put together a few of the bits I've accumulated and serviced ready for this build, no part going into this build is being fitted until it has been stripped down, cleaned, inspected and in some cases replaced or modified.

So far we've got:
THE FRAME:
Forum member Jamie’s former 05 Drz SM will be used as the frame for this bike.

THE ENGINE:
Built from an 06 lump with cases from various engines which have passed through my garage in the last 12 months, its been stripped to the crank and every bearing inspected, every gasket replaced. Top end again from various motors all sealed and timed up tickety-boo.

THE CARB:
Stripped and ultrasonically cleaned before been jetted to suit the 3x3/Pair-Solenoid and use of an after market full system exhaust.

THE AIRBOX:
Modified to suit 3x3

ANCYLERIES:
Standard parts included so far with out modification or significant alteration from OEM spec.
Oil catch tank
Carb to air box rubber boot
OEM air filter – Cleaned and oiled.

All that lovely lot has come together to form this:
http://forums.sv650.org/attachment.php?attachmentid=10488&stc=1&d=1331814419

[Tom_the_great]

Thats the cleanest i think ive seen that place :)

[Owenski]

Thats the cleanest i think ive seen that place :)

Thats because you're only looking at 1square meter of it, rest assured Tom the rest of the shed out of shot still looks like a drz bone yard.

[Specialone]

So what you doing different to a standard supermoto ?

[Roberrrrt]

* Ancillaries ;)

Subscribed to thread

[Paul the 6th]

Can I do the graphics can give it a suitable italian name :)

"Hyperetard"

[Owenski]

Nothing significant with the exception of it having the E model forks, but lots of the little recommended/choice mods such as:

Pair / Solenoid Removed,
3x3,
Aftermarket Full System Exhaust (Arrow),
Jetted to suit the above,
Cap on Coil Kit,
Turkey Baster Mod,
Free Power Mod,
Vapor Dash and Tach Unit,
Heated Grips,
Handguards,
Fan Override Switch,
Edge Tail light,
Manual Cam Chain Tensioner,
LED indicators,

Off the top of my bonce thats about it.

[Owenski]

* Ancillaries ;)

Subscribed to thread

Damn it, word didnt even pick up on that!

[Owenski]

Can I do the graphics can give it a suitable italian name :)

"Hyperetard"

This isnt the hyper-z this is the inbetweener!

This one will just allow me to convert mine into the 440cc dr.
Its got the oportunity to be a 45-50bhp if I can get the exhaust right along with all the other bits. It destroys the 35 the S or SM model puts out as stock.

[Roberrrrt]

Turkey Baster Mod,


Say whaaaaaa?! :smt017

[Paul the 6th]

*sucks air in through teeth*... 50 horses you say? First electricity, then television, compact discs, the internet, and now, 50bhp from a drz.

[Owenski]

Say whaaaaaa?! :smt017
Turkey Baster, you strap it to the rear of the radiator and it acts like in place of the over flow tank which is behind your left calf as you sit on the bike. Its a minor weight saver but it does allow for a large space ideal for a chain oiler or tool kit etc.

*sucks air in through teeth*... 50 horses you say? First electricity, then television, compact discs, the internet, and now, 50bhp from a drz.
Nope, upto 50bhp.
The Epic Speed works models which use nothing more than the stuff Im going to be using have been proven over 50bhp, but these guys are super pro's. I'd be happy at anything over 45bhp...but I dont want to discuss that bike in this thread as it may lead to confusion.
This thread is ultimatly an advert for the one shown in the first pic because once Im done with it I'll be selling it.

[Tom_the_great]

back to topic maybe update first post with what the idea is for a finished bike ie spec output etc ... i know its early stages now but if gives people chance to see what there looking at :)

[andrewsmith]

Subscribed!

Was that the motor you had a drunk YC working on?
Why don't you make the Hypertard(t) a 462 motor

[BBadger]

bah still cant touch a dr350 i say!!
looks good though get more pics up!

[Winder]

Looks tidy so far.

[Owenski]

Today I sorted a k&n filter out, all cleaned and oiled ready for swapping with the OEM one I put in the other day.

Picture of the cleaned and oiled filter shade bathing in the garden.
http://img.tapatalk.com/5e027c1c-08e2-839e.jpg

I also took the carb off and gave that a proper clean in the ultrasonic cleaner before reassembly and popping it back on.

A little picture of it on the kitchen table:
http://img.tapatalk.com/5e027c1c-09e0-d4bb.jpg

FYI, for those who feel like taking a carb apart to clean EVERY bit of it - if you've not done it before keep a camera handy because it very rapidly turns into a pile of very very very small parts. I was most worried that they would fall down the gaps in the ultrasonic cleaning basket.

[Owenski]

Subscribed!

Was that the motor you had a drunk YC working on?
Why don't you make the Hypertard(t) a 462 motor

Yeah I this is that same motor, took me a while to realise what you were refering to then lol.

Many many reasons that the 440 is a better option than the 462, To mak ea 460 you've got 2 options:
Option 1: Use the same piston and barrel as the 440 but get another con and crank kit - Dont really want to go that route.
Option 2: Get the 460 piston and barrel, this is engine suicide for a year round bike, not to bad for the track where it'll get a full service ever run. Im going to use the bike as a commuter all year round, in winter it wont start and in summer it'll overheat lol.

440's are been used all over the world as daily commuters with no issues. Maybe one day I'll build up a Bigbore stroker but only if the bike becomes a summer toy.

AGAIN THOUGH, THATS NOT THIS BIKE!!!

[Owenski]

wow this has been well forgotten about...
I've done loads of updates on the drz forum, I'll get them added onto here too.

[Owenski]

A loverly new set of head bearings were sat waiting to be fitted.
http://www.drz400uk.org/download/file.php?id=1756&t=1
In went the races which for the first time in my life was not the pig of a job I've come to think it may be.
http://www.drz400uk.org/download/file.php?id=1757&t=1
ohhhh they look loverly when new.
http://www.drz400uk.org/download/file.php?id=1758&t=1
Now the yolk fitted into the headstock such lush movement, and as a bonus this took less than 2hours start to finsih so I had plenty of time to do someother bits so decided to connect up all the carb and air box again having removed them to give me easier access to the rear shock and swinger linkage.

[Owenski]

I've not been posting on this for a while but that’s purely because typing up can take so much time, the build has still been on going and so have the pictures.
I’m actually riding this bike now so as far as it been a complete and road worthy DRZ, that much is complete however the modifications are not. I didn’t get chance to service the forks or brakes and none of the modified/additional electrical features are wired in, anyway... here is where I've gotten as far as the upgrades/service/rebuild stuff is concerned...

[Owenski]

Next on the list was to sort the exhaust out, the system which came with my bike was a full arrow one which the previous hamfisted owner had unfortunatly installed using jubilee clips and bruit force causing this effect at the coupling.
http://www.drz400uk.org/download/file.php?id=1744&t=1

That lead to massive pops and horribly embarrasing riding through city traffic, so I decided to use a stock header and end pipe connection and weld these onto the Arrow pipe work ensuring an air tight joint.
http://www.drz400uk.org/download/file.php?id=1745&t=1

I chopped off the ends of the standard pipes, and also chopped back the arrow pipe work to ensure the knackard bit was gone but also that the pipes remained the same lengths so the geometry remained the same.
http://www.drz400uk.org/download/file.php?id=1746&t=1

With the two systems butchered I set about welding (mig: 80/20) the pieces all together. This was the first untidy effort before I cleaned it all up and ground it down a bit to smooth things out and make sure the weld wouldnt comprimise the joint.
http://www.drz400uk.org/download/file.php?id=1747&t=1

[tigersaw]

That lead to massive pops and horribly embarrasing riding through city traffic,


Thats a mod I'd put on mine

[Owenski]

This is what it looked like after a little cleaning up a little.
http://www.drz400uk.org/download/file.php?id=1748&t=1

I needed to check how air tight the weld would be so thought this was a fairly decent method of testing the weld.
[/URL]
http://www.drz400uk.org/download/file.php?id=1749&t=1
Needless to say it took a couple of attempts to get it right but when I did I then progressed onto the end pipe piece which finsihed up looking like this.
http://www.drz400uk.org/download/file.php?id=1750&t=1
(http://www.drz400uk.org/download/file.php?id=1749)

I did think about chasing the weld up the pipe and continuing how I'd blended the pipe work together so it may appear seemless but instead I decided to stubby the end can and here it all is connected up on the bike.
http://www.drz400uk.org/download/file.php?id=1751&t=1


You can see in this picture that I've stubbied the end can, I dismantled it entierly and removed all the packing and stock rivots. I've repacked using some new wadding and then re-rivoted with new stainless ones. I needed new rivot holes drilling at the outlet end so added a few more rivets for good measure but Im chuffed to bits with the finished article.
http://www.drz400uk.org/download/file.php?id=1752&t=1
[URL="http://www.drz400uk.org/download/file.php?id=1752"] (http://www.drz400uk.org/download/file.php?id=1751)

[Owenski]

A little less concentration and thought were required for the next part of the project as I added a swing arm and rear shock. The swing arm taken from the drz I'd been using, this was a former S model which I'd modified to take the SM swinger.
You can see in this pic there is my 06 S model in the foreground and the feature bike (inbetweener) is on the stand up towards rear of the pic, prior to me finishing the exhaust and fitting the rear end.
http://www.drz400uk.org/download/file.php?id=1753&t=1
With a LOT of cleaning the swing arm came up like this, I dont know if it can be seen in the pic but the bearings have also been removed and new replacements fitted... that wasnt easy either - all in all I did not enjoy the swing arm work lol...
http://www.drz400uk.org/download/file.php?id=1754&t=1

This rear shock had previously been removed from one of the bikes I've broken and had stripped down and cleaned up, checked and adjusted to suit a 13stone rider (average) the combination of which when fitted to the bike and tourqed up looked like this:
http://www.drz400uk.org/download/file.php?id=1755&t=1


Note I'd removed the exhaust after headbutting it a few times.
As mentioned above, I've quick fitted the rest of this back together so I had still had a bike to use but service and repair work will start happening again now I've finished uni.

[Owenski]

Thats a mod I'd put on mine

Oh no mate it was rediculas - it wasnt a nice popopopoppp it was brutle BANGbrrwrwrwwprpppBANGpopopBANGbbberbeppp brwp brwp BANGBANG BANG.
Bloke at work said it reminded him of the trotters 3wheeler.

[andrewsmith]

Oh no mate it was rediculas - it wasnt a nice popopopoppp it was brutle BANGbrrwrwrwwprpppBANGpopopBANGbbberbeppp brwp brwp BANGBANG BANG.
Bloke at work said it reminded him of the trotters 3wheeler.

SV with a full M4 brutal? :rolleyes:

[Owenski]

SV with full M4 sounds loverly, nice and powerful crisp noises - seriously it was a real head turner for all the wrong reasons... not anymore though :) stubby arrow exahust is the nuts!

[Owenski]

For those following this in the other posts I've made will have seen some difficulties with the running lead to a few breakdowns.
Saturday saw the MOT test date arrive and so I had to fix the bike for good, Friday night I therefore fit the FCR carb on and that seems to have fixed everything confirming that the problems were infact carb related.

As it stands now I've got the dynojet stage one Kit on order, once that arrives it will be installed into the SV carb and that fitted to the bike. The bike will then be fit for sale although I'll still be holding onto it until the other bike is built and I no longer need this one.

[andrewsmith]

Time for a full rebuild of the carb!

I bet you the bowl is full of junk

[Owenski]

No, its literally its been through the sonic cleaner twice in 4months the carb is clean as a whistle, its more likely that I didn't have a problem before because a clog was restricting the air flow. Having cleaned the carb I removed the blockage and allowed more air through causing it to run technically better as a carb but not suited to my set up.

Im now certain the problem has been that the jetting is way off, when it ran the stock air filter and the paj165 the mixture was forgiveable but as soon as I put on the K&N it allowed the airflow to cripple the carb. The top end running of it was dangerously lean, the spark plug proved that. Now I'll be able to fit the correct jets and the more suitable 135paj it "should" be running sweet.

[andrewsmith]

Fair enough

Plug bright white?

[Owenski]

Aye, bright white and the tip starting to look a little fecked, it must have been insanely hot!

[andrewsmith]

lol

have a read of this page! http://www.theultralightplace.com/pistons.htm