2005 Dr650se (12,000 miles)

I bought this DR off some kids middle of nowhere for 2500 bucks. It was a 2005 with 3500 miles, or at least stated. The bike looks really ratted and abused. But my goal was to swap nearly all the components on it to begin with, so I didn't care so much for the stuff that were broken. At the end, it was a good deal given that I was removing almost everything off the bike anyways. If however, I knew more about the bike and details of the bike, I might have try to haggle the kid down to 2000 dollars. But then again, I probably would have bought it at 2500 anyways. Solid bike, just neglected and treated poorly. This was my first frame off restoration and upgrade build.

I striped down the bike little by little, it was my first time stripping down the Dr, but more importantly first time stripping down a motorcycle. I took quite a few photos of each process just in case I don't remember where things go. I did learn a lot about each part of the motorcycle. 

I didn't find too many surprises when I stripped the bike, but I did find a few. The plastic cap cover for the main relay was missing, so I ordered it. Tool kit was missing, so there was no stock tools or spark plug remover. The bracket that holds the battery down was also missing. So I had to order that. All in all, it was 15 bucks on Ebay for it all. 

It was a bit tricky getting the bike off the ground for the first time. Since then I have learn alot better ways than what I did here. But being it the first time, this was how I propped it up. I'm was surprise how simple the bike is, the wiring is intuitive, and the parts are easily removed with simple tools. 

then I had to moved the engine out, that was bit complicated. It took a while of me fumbling around to get it out of the left side. Even with the tutorials and forum directions, it was not that straight forward. I did eventually get it out, and I noticed there was alot of surface rust on the base of the frame. 

Jeff helped me cut a few reinforcements. And he helped me welded on the Dr. Also noticed that the steering stopper piece was broken/damaged. Jeff build slag from the welder and then later, I clean and grind it flat. Bike must have been dropped and crashed pretty hard at one point, but there is no damage otherwise. 

I sanded the frame, then prime and painted the frame. After it was dried, I wrapped it in paper before I install the motor, so I don't scratch up the paint. It took forever for me to get the engine back in, another newbie learning curve. But eventually things are getting back together. I used VHT frame paint, and VHT metal primer. Spraying it was a a hot mess, especially in the winter. I end up using drop cloth all around to block it. 

DG-O exhaust came from ebay. I sanded and painted the header. Later I realize very quickly, the painting was very irrelevant if you ride off road. I also found out I lost of the bolts holding the heat shield, so I had to order another bolt, and I loctite them on. I painted the cover as well. 

Suspension modification was pretty easy. The shock body came out with two ring clips, and bleeding it was a bit of a mess the first time. I redid it twice, cause I was trying to make sure I did it properly. Probably used up more than I need to on the shock fluid. After I was done bleeding it, I realize I need to pressurize the reservoir to 195 psi of nitrogen. I could not find a single soul that does it around here. Finally I was able to find RAM cycle in Gaithersburg to do it for me for 10 dollars. 

I got the moose racing adventure seat, painted the calipers and then did the front forks with the Cogent DDC emulators and up-rated springs for my weight. I bought IMS superstock pegs as well versus the mini pegs the stock dr came with. 

Exhaust was fitted, the mounting hole for the exhaust bolt was not the same as the oem one. It also is kind of the wrong size and semi stripped out of the box. It's what you get for cheap exhaust on ebay. DSA rear fender for the supermoto look. Stainless steel brake lines, renthal handle bars. and some cheap ebay mirrors. 

I learn very quickly that the ebay mirrors breaks very easily. I broke it twice and bought another two sets, I should have just bought a double take version. I suppose if you never really do any offroad the mirrors can work. Polisport headlight was also added, moose racing fork sleeves, and the nomad rear rack. Acerbis 5.3 gallon tank with 2 petcock. LED turn signal throughout, and YZ front fender. Moose racing guards with moose racing hand cover and the procycle extensions. 

first test ride was successful. Got it inspected and had zero issues with it. 

until... about day 2, during a test ride, I couldn't go above 30 mph. I was on the interstate. I was able to limp it home, but it was pretty dicey moving over on the freeway. I upgraded to outlaw racing clutch pack with barnett springs. I also checked the NSU screw at this point and it was so tight I couldn't even turn it. It confirmed the mileage of the bike. I would check it again in 12k and it was not even finger tight. 

I always had starting issues, it would randomly not want to start. So finally I took the starter out and apart. To my horror, it was loaded with water. Not to mention all the contacts were bad as well as the seals. The commutator was badly worn. So I end up doing the best I can and fixed it back together. Later I would replace the whole starter, as it was too badly worn.

When I returned from Colorado the carburetor decided to flood. Luckily I was in a gas station and jeff was riding with me. We picked it up with the truck and dropped it at my house. I opened the air box and tons of fuel came out. The pilot needle was definitely bad. 

Also replaced the bearings, for the wheel. The rear ones were terrible, waiting to fail. The fronts were fine and didn't need replacing. But I replaced it anyways. The bearing replacement was pretty easy. No special tools just a hammer a drift and some large sockets. 

This Dr650 was my introduction to off-road riding. I was hooked. Once I went off the beaten path, riding fast on the road lost much of its appeal. I started searching for the next real adventure to the road less traveled. I found the adventure within me, and its power was a lot stronger than the need for speed.

Later I sold the bike to Windham Taylor who rode the bike to Argentina, many times on the road together with my other Dr650. Now the bike in Tennessee, still thumping along.