HadesOmega Preps CactusPuncherDR650 for LAB2V 2018

[budman]

Damn Merlin. That is a lot of work. Good on ya!!

 

[HadesOmega]

So I need to adjust the chain but the suspension is topped out. So I remove the carb boot and lower the preload on Excalibur. After loosing so much weight I backed off on the preload a probably about 5 full revolutions. Wishing I sprung for that hydraulic preload adjuster now =P This is another weapon I have for LAB2V. Excalibur exclaims "BRING IT"

When adjusting the chain I realize the right chain adjust is put on backwards. It's no big deal I guess it works either way.

My offroad lights aren't working anymore. Will definitely need these as the days are short and I'll need the best lighting I can get if I get caught riding in the desert at night. I must've pulled the wire out of the trail tech switch.

Since we're working on the electronics time to see if the GPS plug still works, GPSmap78 ready for battle!

Checking heated grips, it's gets really cold in the desert in the morning and evening. Very handy having onboard voltmeter notice the switch positions. Looks like I need to charge the battery also '

 

[HadesOmega]

Air filter cleaning time. Haven't cleaned it since NevadaBDR and the filterskin is pretty filty. I suppose it's not that caked up with dirt but want to have a fresh filter for LAB2V. So I have decided I will run without a filter skin. Just the airfilter for LAB2V, I will be riding solo so I won't get dusted too bad. Of course that doesn't mean that I won't be following the other 300+ riders out there. Hopefully it'll be fine. If it get's too dirty I will take the filter out and shake it and maybe wipe it with a napkin.

Still clean in there =) I noticed one part wasn't sealing so well, will have to make sure the cage is in the right position when I put it back. Also this unifilter seems to have seen better days. I have cleaned it so many times that the foam seems to not be so crispy anymore. Kinda like how a dish scrubbing sponge gets worn out. Plus you can't see the UNI logo on it anymore. Will clean the filter later another thing I have to address..

Is an oil change. Checked my maintenance records and I changed the oil 2800 miles ago. So it's pretty close better change it now and I'm glad I did the oil was pretty filthy. Ahh memories of changing my oil on the TAT, but it's nice to be able to do it in your garage.

Not super dirty but not clean either

One little sliver of metal on the drainplug '

I find it funny how I have like 3 different bottles of oil here. The Castrol bottles have different graphics on it hah. I'm also out of oil, will have to pop my head into autozone or walmart every once in a while and stock up on the cheap stuff.

 

[HadesOmega]

I'll just put this right here if case your wonder how much does the CactusPuncher weighs...

[YOUTUBE]0K6ScFlsAAQ[/YOUTUBE]

 

[SFMCjohn]

Here's the results looks like a brand new chain or so I thought...

So I take the B&B Offroad countersprocket cover off and I see something alarming. It's an O-Ring. Presumably from the chain!

So time to inspect the O-Rings on the chain and it's no bueno the chain is missing MULTIPLE O-Rings not just that one. So my chain has been flinging O-Rings for who knows how long. Some are cracked and pieces missing also. Check it out. So hard to tell they're missing though wish they made pink or lime green O-rings =P

That's not a new chain also, that's the one I got from a shop in Georgia. WD40 really worked good. I figure the chain will get me through LAB2V and back to Palmdale and going to chuck it when I get back..

cheap Uncle John sez "Merlin, please don’t run that chain ..."

 

[HadesOmega]

Time to replace fuel lines. They polurethane fuel lines last for about half a year and you gotta replace them. The smaller line looks like its about to start splitting. I replace the longer one because it did split not too long ago but they're all yellowing already.

Ran out of fuel filters so I headed out to cyclegear to get a new one. I've seen these get clogged and you can't really tell. I don't remember the last time I replaced it so might as well do it now.

 

[HadesOmega]

Air Filter cleaned and oiled

Time to replace my old rollchart holder. My old one got busted up on the NevadaBDR when my bike fell down somewhere and smashed it in my pannier. Was going to use it to do the Idaho TAT but never made it. I went for the Moose Racing one this time. There are some things I like about it and some things i don't don't. For one thing it requires the use of tape. Really Moose!? You couldn't just cut a slit in it like the last one I had?

So I set to modify the mounting system. It has the same clamp down mounting system, I modified my previous one to take a ram ball mount. I ground down the rivets holding it to the body.

Now I have to drill new holes to mount the ram mount

Like it was before I wound up rivetting it. I couldn't find the perfect size screw. Hopefully this holds up, the plastic is pretty tough on this. I will bring some bolts just in case it falls off =P

Finished! So this on you take the sides off and slide the rollchart in as opposed to rolling it in. So should make changeouts faster. Crappthing thing is I need to bring tape with me.

 

[HadesOmega]

So I've decided on a tire combo for LAB2V. I will run a Dunlop D606 in the rear and keep the current TKC80 on the front. I've never ridden with the D606 so we'll see how it does. I rode with a dude that had a KLR650 on the TAT that used them and he said they're good but they track a little too well. So i have THREE D606's that I somehow acquired for free. This one in the picture I got with this spare wheel I bought. It has the most meat. I didn't want to run something brand new because I need to burn through tires I got quite a tire collection going. These I'd say are at 70%. I need a tire that can get me through LAB2V and then slab it from Vegas to Palmdale. So I don't want to burn up a new knobby doing that. I want to throw these away when get home basically.

I finally get to test out my Heavy Duty Motion Pro Beadpro. They are awesome. So surpsingly the D606 was not difficult to install at all. However the Shinko 805 I took off fought me quite a bit. Turns out the Shinko is a 130-70-17 and the Dunlop is a 130-80-17 so that might be why it feels so stiff lower profile. Great my bike is going to be even taller now =P But it wasn't too hard to install even with the rimlock and ultra heavy duty tube.

Shinko805

Cheated a little I used a heatgun to warm the tire up a bit

Slide it on pretty easy. I had to use a tire lever to get in the rest of the way.

tadaa, the bead even seated easily too! Thanks D606 for painless install =P

Balance wheel, it took 4ounces to get it sorta balanced!

I mark down however many times I used the tire changer or balancer to remind myself I'm saving hella money doing this myself.

 

[FoolishMortal]

Excellent work so far!

I'm a little worried about your plan to strap tools to your body, though. If you go down, you don't want to land on sharp/hard objects if you can help it...

 

[HadesOmega]

Yeah I don't like the idea either. But when I trail ride on my dirtbike I usually have a small camelback with some tools. It should be fine as long as I don't have a highspeed off. I'll definitely have a sweaty back also =( . I'll see if I stash some stuff on the bike, I will have the tank panniers on still.

 

[HadesOmega]

Time to fix that muffler and leaky headgasket. So I broke the muffler clamp it was seized

I could not get the headpipe out all the way but enough to get to the nut where the head is leaking.

Looks pretty good in there

So what's happening here is this nut works itself loose and then it starts leaking oil and it starts dribbling to the back of the head.

 

[HadesOmega]

Here is the nut in question, I could tighten the nut a little bit with the exhaust in the way but not very well. Hopefully tightening this works

Cleaned all that oil and dirt off with engine cleaner

I made sure and tightened it really snug. It feels like it's bottoming out though. It suddenly just stops and you can't tighten it more. So I've tightened it as tight as I could and I slathered a bunch of threadlocker on it. Hopefully this works. It's only suppose to be torqued at like 14 ft-lbs also '

 

[HadesOmega]

GSXR1000 Muffler

Keintech Midpipe, this is a collectors item now. Notice how much it necks down for the headpipe. I could probably get more flow if I got a better headpipe.

Gasket looks OK, probably should change it in the future

Busted seized clamp going to replace with a hose clamp

Time to fix this oval'd muffler mount. Like my military grade HadesOmegaSpec muffler mounting plate? So couple problems goings on here. The plate and the muffler have oval'd out because the vibrations and solid mounts. So my plan is to bore the holes round again and add gromets so it has some kind of vibration dampening. Also notice the muffler is rubbing on the plate I'll add a gasket between the two to stop the chaffing.

Gromet

Gasket is made of silicone hot pot mat I bought at Daiso for $1.50

Put it all back together, hopefully this helps with the mounting and vibrations. It still feels stiff. Will have to check it out after LAB2V.

Wheel goes back on, Ohhh look at those knobbies looks like the Cactuspuncher is ready to battle the dirt! D606 Rear and TK80 Front small block knobby action!

 

[HadesOmega]

So when I was working on the chain and replacing the countersprocket I noticed this. I never noticed it before so it may have been like this for a while ' There's a hole in the swingarm chainslider! It's also starting to dig into the swingarm, fortunately no hole! This isn't a part where the chain rests on also so my only guess is the repetitive swingarm action the chain whips this spot over and over until this happens.

So still more than a week to go I use the ebay magic and located a used one that's in better condition than mine. Found one for $25, buy it now and it's here in less than week. I think that is the DR650's greatest strength is used parts availability and aftermarket! I can easily find used but still usable parts on the interwebs because Suzuki made sold so many of these machines My buddy has a 2009 BMW F650GS Twin and you hardly find any parts for that bike you'll have to go to the dealer and pay $$$.

Removed old chain slider not too hard. It is held in by button head phillips head screws. I had to use an impact driver so I wouldn't strip them. The previous owner of this bike oddly replaced the bottom screw with a allen head bolt, makes it easier. I had to remove the airbox to get the top ones out.

Side by side

Here's where it's mounted kinda dirty from all the lube and dirt

Cleaned the swingarm up a bit. Looks brand new EXCEPT underneath the slider. It's all pitted. My guess is the sand/dirt gets under the slider and starts pitting it like 8grit sandpaper.

Installed the newer one, you can't see it but I used a button allen head bolt on one of the top screws so if I need to remove it I don't need an impact driver and airbox removal.

 

[HadesOmega]

LAB2V right around the corner. I will admit I am about one task behind everyday but I should make it. Next is to setup the preload but before that I need to get my riding gear ready. For LAB2V I am rocking my adventure gear. I know it's going to be cold, the adventure gear is great for climates 30F to 100F I know I've tested it So to set the preload I gotta wear all this, or I suppose I could weight it all and stuff some weight into a back pack when I set the preload. Rockin the Olympia Dakar and I'm taking BOTH cold liner and wet/wind liner. Last time I didn't take the wind liner and I paid for it chilled to the bones because the cold linear doesn't block the wind it goes straight through it. I had heard a rumor that the 2017 LAB2V was not as cold as it was in 2016 hopefully that will be the case it's miserable riding in the cold until that sweet sweet sunlight comes up.

Gloves I will take 2 pairs. I will have a 3rd pair for when I go home if it is freezing. Still rockin the youth goggles. Gloves are Racer Rally Gloves, love these gloves I literally rode the whole TAT with them. Then there is Knox Nexos for street duty and if I need a warmer glove. I don't think I'll really need the cold weather gloves because I have heated grips. Then to top it off or more like bottom it off I have my Risk Racing anti blister gloves. These are great and prevent blister because we'll have to twist more than 100X times!

Helmet Caberg Tourmax, still rockin my old buddy here.

 

[HadesOmega]

Sorting the gear I will be taking with me. Yeah Merlin bring too much stuff =P

This is the stuff from my dirtbike trail pack that I will be taking

These tools will be stored in the tank pannier so they are easily accessible.

Gotta go through the rotopax also, basically all I'm taking from that is the tire levers and tire stuff. All my bikes have a specific tire repair kit that I assembled for them.

More stuff added to trail pack

Oops this Tusk sparkplug holder only takes one spark plug, I forget the DR650 has 2

This stuff will go in the stock DR650 tool tube

Trail pack all loaded up

 

[HadesOmega]

The trailpack weighs about 11lbs not too bad

So I strapped this fenderbag that has my 17"tube in it and my tire irons and 14T sprocket

So the 21" was in my rotopax where do I put it? Stroke of genius I wrapped it in this MRE bag and zip tied it under my tail rack. Another benefit of this is it presses down on my rear fender a bit so it'll keep it from flopping around.

 

[HadesOmega]

Now the bike is loaded time to adjust the preload, got my gear on!

Here is my preload adjusting apparatus

An arrow through the axle

A camera on a tripod and a tape measure

Measuring full rebound, so here's what I did. I set the sag at 2.5". You're suppose to set it at 3" on this bike but it doesn't have much fuel in it, plus I'm sure I might be adding more weight somehow =P. The full extended stroke I measured from the arrow to the grab handle is 22". So 22" - 2.5" is 19.5" So that's my target. I sat on the bike and recorded the with the camera how much the sag was. It was 19.75" when I replayed the video. So actually too little preload. I loosened the adjuster too much. So I turn the collar 2 full rotations and I guessed right next measurement 19.5"! Bike is good to go!

So not much of a proper shakedown and it's raining outside. I take the DR for a spin around the block and all seems well. Cactuspuncher is ready to take on LAB2V 2018! The battery did need a jump I hope it will be fine when we start rolling. I brought my jumpstarted just in case and I will be fully charging it, I usually keep it at storage voltage.

But wait there's more! I forgot to remove my old LAB2V sticker. I'm sure it will just confuse them. This sticker has been all over the country. Also I have a new sticker to put on a Cactrot or Cactaur from Final Fantasy! Why because watch out Cactuspuncher is coming to get you!

One more thing to check is the countersprocket retaining plate to see if it is rubbing on the chain because I put a smaller countersprocket. This seems to be fine, it is really close. I also lubed the chain, I will be liberally lubing the chain throughout the whole event!

That's it I head for Palmdale in a few hours! IT'S GONNA BE AN ADVENTURE!

 

[1962siia]

Have fun Merlin!

 

[SFMCjohn]

Have fun Merlin!

+1, wish I was going with you!