2006 DL650 Naked Weight Loss with numbers ! - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 52 Old 12-18-2018, 03:35 AM Thread Starter
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2006 DL650 Naked Weight Loss with numbers !



Hi to all Stromtroopers ! this will be my first post ever and it will be interesting, i hope ,

i Bought a well maintained dl650 2006 for some 2500$ with all paniers and rack to go in trip this summer, but i found that this pig was way too heavy to my taste , so i decided to wreck it apart and make a good winter project and share it with everyone

i will show you how i drop the weight from 491 lbs wet to 420 wet ( not finished yet )

i'm open to all idea's you can give me
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Last edited by Yvon Nulpart; 01-06-2019 at 05:01 PM.
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post #2 of 52 Old 12-18-2018, 09:04 AM
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I'll agree that removing the gas tank, especially if it were ful,l would be a great weight loss.
The battery is worth a few pounds too.
I had a 2001 BMW RT-P and removed a lot of the extra metal work the authority bike has and lost 30 pounds easy. It was still a heavy beast.
In making your changes are you just making a commuter or a play bike?
You could recoup some of your investment selling off the unwanted bits.
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post #3 of 52 Old 12-18-2018, 12:22 PM Thread Starter
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numbers for the weight, more picture to come :)

for the weight in KG , Simply divide by 2.2, EX: 45lbs / 2.2 will be 20KG for the gas tank


tank full of gas : 45lbs

Complete Front wheel with Shinko 804 dual disc and tire : 29lbs / 13kg

fairing with turn signals, speedometer and faring frame - 20lbs

pannier racks - 15 lbs

subframe : plastic fender 1.8lbs, metal 9lbs - 10.8 lbs

exhaust = i cut at the headers - 10 lbs

battery 9,2lbs

Seat : the plastic of the seat is 3 lbs, 2.2 lbs of foam and 1 lb for the seat cover - 6,2 lbs

passenger pegs - 4 lbs

mirrors and end bar weights : 4lbs

rear fender with turn signals - 4 lbs

Calipers: 2lbs each / 0.9kg

Laterals plastics 1lb each : 2lbs

bracket for center stand + bolts = 1 lb

Front Wheel axle 1lb / 0.45kg


at this time, i fabricated a muffler , with car exhaust tube , rock foam insulation and tube of holes in to pack this foam, bought a lithium battery that weight only 1.7 lbs, and i fabricated an aluminium subframe from 3/4 x 3/4 x 8 foot tube at home depot for 21$, that weight only 3 lbs

hope you enjoy :P, to be continued
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Last edited by Yvon Nulpart; 01-06-2019 at 05:02 PM.
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post #4 of 52 Old 12-18-2018, 12:29 PM Thread Starter
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Notacop, this will be my adventure motorcycle for going in trip this summer, because i wanted a cheap, reliable and lightweight bike that is capable of doing some moderate offoad, i did not mention that i've put dr650 fork tube in the stock cartridge and it added 3" of ground clearance, i also lifted the rear by 3" by fabricating an shorter aluminium linkage dogbones, off course i have extended the side stand
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post #5 of 52 Old 12-18-2018, 03:12 PM
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Quote:
Originally Posted by Yvon Nulpart View Post
Notacop, this will be my adventure motorcycle for going in trip this summer, because i wanted a cheap, reliable and lightweight bike that is capable of doing some moderate offoad, i did not mention that i've put dr650 fork tube in the stock cartridge and it added 3" of ground clearance, i also lifted the rear by 3" by fabricating an shorter aluminium linkage dogbones, off course i have extended the side stand
If you lifted the rear by 3" how did you modify the swingarm for chain clearance?
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post #6 of 52 Old 12-18-2018, 05:29 PM
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The previous owner of my '04 650 reduced it's weight by 40-50 pounds. He did it just off a curve at 90+ mph.

And, so....

I have done the DR650/DL650 hybrid fork. If you got all three inches of possible increase, then you now have very little overlap of upper and lower tubes at full extension. I would be very wary of that. If you add a spacer next to the top out spring, you will gain less height but you will gain some distance between the bushings at maximum extension. Such short distance between the bushings is bound to promote binding rather than sliding. IIRC, I opted to gain only 1-5/8" or 1-3/4" in travel. I have 30K miles on this set-up now.

I assume you used the DR damper rods. But which springs did you use?
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post #7 of 52 Old 12-18-2018, 05:41 PM
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Be very careful with aluminum dog bones. The bones are a highly stressed part and I have seen steel after-market bones fail. Personally, I would use steel for this part....it is not worth the savings for the strength difference.
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post #8 of 52 Old 12-19-2018, 02:26 AM Thread Starter
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Thanks

hi , thanks for your comments and advice, i agree with STCorndog, for steel linkage, there is no option for security , and effectively it looks like the chain will rob the swing arm with this level of suspension raise , so i will need to lower a bit or maybe 1t up front sprocket could help, as for the forks yes, i have used dr650 damper rods with spacer otherwise the bike was a crazy cruiser , it add about 3inch ground clearance and 1,2 inch fork travel, here are some pictures
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post #9 of 52 Old 12-19-2018, 08:46 AM
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You can use 7075-T6 aluminum. It is stronger than most steels, but not the common 6061-T6 unless you make 3/8" thick and use longer bolts.

Seriously though, you are creating some problems for the chain. You can not use the standard chain tension spec and method as the chain will be too tight at its tightest point. That would be when the swing arm pivot and countershaft and rear axle are in a straight line. Also be sure that the chain is not rubbing n the swing arm at any point in its travel.

For some inspiration google sv650 enduro and hit images.

The search SV650 Frankenbike.

5 Custom Adventure Bikes Built By "Real People"

The above are all easily do-able, this one would be really cool, but a lot of custom parts wouldneed to be made.



This one seems do-able.

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Last edited by richlandrick; 12-19-2018 at 08:49 AM.
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post #10 of 52 Old 12-19-2018, 09:17 AM
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That pinner exhaust looks wild. Would love to hear a clip of it running
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