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Yut-Ughhh
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1,651 Posts
Discussion Starter · #1 · (Edited)
For those of you that know me or that I talk to on facebook, you probably have heard me spout off at one time or another about making MY perfect supermotocommuter.
I LOVED my XR650 supermoto, and my DR650 was great also, but neither were very well suited to how and where I like to ride.

So here is my attempt at making what I want---I typed up a few paragraphs explaining why, but then just backspaced it all, it doesn't matter what I explain about it. I'm building what I want and I'm sure many of you here will understand, and if not, IGNF.
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Dirtbike rolling chassis-CHECK.
17" wheels- CHECK.
6speed transmission motor- CHECK.
Cheap, plentiful, and easily beat on motor that can take hauls down a highway- CHECK.


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Step one- Start with cleared off bench.



Step two- acquire motorcycle, and be pleasantly surprised it has 2-1 SS full exhaust system.


Step three- unload motorcycle out of truck. (2005 EX500 with 5k miles on it)



Step four- eyeball and continue with more measurements



Step five- unbolt and toss motor up on workbench.



Step six- chop and start fitting frame.



hmmm close...






Step...Uhhhh oh. problems....






And the end of day one....just for kicks and giggles and grins :rock:
 

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BLACK BELT
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7,072 Posts
Can you get the engine level and the front sprocket level with the swingarm pivot?

Front sprocket looks to high in the pic.

Make it fit! :D
 

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ER6Ninja Warrior
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198 Posts
This.... Is going to rock. Been looking at options for my 650R to be a dual sport/motard today. Meh...
 

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Yut-Ughhh
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1,651 Posts
Discussion Starter · #7 ·
Can you get the engine level and the front sprocket level with the swingarm pivot?

Front sprocket looks to high in the pic.

Make it fit! :D
Hey thanks for swingin by smoker....I'll let you know now, this build will probably have ZERO titanium, lol aluminum is about as good as it gets here lol. Your builds are lookin awesome by the way, get those things on the road!

And yep to both your questions as you will see here in my next post. Those were just the first test sessions seeing where things ended up fitting exactly once I started cutting. :rock:
 

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Yut-Ughhh
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1,651 Posts
Discussion Starter · #8 ·
So yesterday I spent quite a few hours adjusting and checking and moving and fitting the frame around the motor the best I could....

Here is how I was able to best get the motor to fit, with the chain line 100% perfect.
Problem with the motor here is it is mounted forward in the frame more than I would like it to be, but I run into alignment issues with the chain if I move it rearward since there are clearance issues with the carbs between the frame rails and also with the valve covers.
How badly forward mounted do you think this would be?





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Rough idea I have on how to do the front mounts.
-Make a one piece cradle to go from the two bolt holes on the frame around the motor and down to the front engine mounts and back up the other side of the bike (it's symmetrical)
-And then it isn't displayed very well, but the top mount I am thinking weld two tubes to the frame near the steering stem to triangulate the mount and have it be gusseted, and then connect to that mount with another bracket holding the motor up from the those two bolts in the head of the motor.

-----I am quite open to ideas on how to best do the front/top mounting of this motor, MSpaint away if you wish!:thumbsup:





And then I made up some quick bracket/tabs for the bottom rear motor mount so I can at least get the motor bolted in the rear and then I will jig it up in the front so I can put wheels on this bad boy to see how the motor actually sits in the chassis once it is on the ground.


(I'm aware this bottom one here is not an ideal load bearing design lol)
 

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Yut-Ughhh
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1,651 Posts
Discussion Starter · #9 · (Edited)
Goal for the weekend was to throw wheels on it and see how it roughly sits- 2x4 rear shock and all.
Goal accomplished in about 3hrs, rear motor mounts went pretty quickly and then just had to grab wheels and throw whatever fit between them.


So first thing was tossing wheels on it.



Then I picked it up and set it down off that bench by myself. Brute strength lol :napoleon:




Motor looks like it sits a bit more forward in the frame than I would like in this picture, but if you look at the next one, it actually is tucked in there fairly close on the other side.



Sprocket and chain line are DEAD on. Motor also feels and looks to sit quite low and the weight seems to feel very nice and NOT top heavy at all.




First end goal will be to get this bike on the road as quickly as I can...which means leaving things as close to stock as possible, so I'll probably be running the exhaust like so.
---FYI----Wheels on it when it first goes down the road will probably be spoke SM CRF wheels for ease of fitment.
 

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Premium Member
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282 Posts
Fuck yeah!!Looks like an interesting project...Amazed at how many projects you have done in the past few months!!Got my hands full with my two Ive got on the go!!!
 

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Yut-Ughhh
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1,651 Posts
Discussion Starter · #12 ·
Top and bottom rear engine mounts, should also be getting tied into the swingarm pivot bolt VIA steel plate.... if it all fits... which will make the engine mounting incredibly solid.

I'm thinking about doing something like this for the front motor mounts.
 

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Yut-Ughhh
Joined
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1,651 Posts
Discussion Starter · #13 ·
More shall be coming soon on this build. I've got the entire frame/motor mounts done and drawn up and I also purchased a bunch of PVC and some wood this morning for the prototype
:rock::rock::rock:

First thing is actual rear motor mounts, working at a one piece design for both top and bottom rear motor mounts.
I had about 5hrs of sleep, I'm too excited to get this thing bolted up :Evil_smile::lotsocoffee: :lotsocoffee: :lotsocoffee: :Evil_smile:
 

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Custom bikeporn addict.
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1,241 Posts
More shall be coming soon on this build. I've got the entire frame/motor mounts done and drawn up and I also purchased a bunch of PVC and some wood this morning for the prototype
:rock::rock::rock:

First thing is actual rear motor mounts, working at a one piece design for both top and bottom rear motor mounts.
I had about 5hrs of sleep, I'm too excited to get this thing bolted up :Evil_smile::lotsocoffee: :lotsocoffee: :lotsocoffee: :Evil_smile:

Hey man. Just a thought but:

If you build the mounts as a wrap around 2 part frame, you can incorporate a small bash guard underneath, and it would be easier to take apart.

I know you plan to use it as a commuter but with how exposed the headers are, and the oil pan if you do move the headers, it seems like a worthwhile addition. Especially seeing as what you are building is an awesome dual sport. So being able to just toss on knobbies and take it out would be really nice.

Bob
 

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Yut-Ughhh
Joined
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1,651 Posts
Discussion Starter · #17 ·
Hey man. Just a thought but:

If you build the mounts as a wrap around 2 part frame, you can incorporate a small bash guard underneath, and it would be easier to take apart.

I know you plan to use it as a commuter but with how exposed the headers are, and the oil pan if you do move the headers, it seems like a worthwhile addition. Especially seeing as what you are building is an awesome dual sport. So being able to just toss on knobbies and take it out would be really nice.

Bob
Thanks for the input Bob, I most definitely do plan on making a bit of skidplate for it...cuz you're right I'll be tossing some knobbies on here also at times!:party-smiley:
 

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Yut-Ughhh
Joined
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1,651 Posts
Discussion Starter · #18 ·
I put on the DW gloves yesterday and did some CRAZZZZYYY progress....Idk if you guy are ready for this....


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I made a wooden box!!!!!! OMG OMG OMG! lol
:wtf::wtf::wtf::wtf::wtf::wtf::wtf::wtf:



:D:D:D:D:D:D:D:D:D:D:D


And then I brought that box my mini-garage, and all a sudden my EX500 motor jumped onto it and said

IF I FITS, I SITS!



Then I did some more fiddling with the frame and I got this artsy farty picture.....that shows sprocket and swingarm bolt location in a very nice spot....3.5" center to center.
 

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ER6Ninja Warrior
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198 Posts
I always thought that if I dual sported my ER6N, that I would HAVE to find a new way to route the exhaust. You would gain so much ground clearance!
 

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Yut-Ughhh
Joined
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1,651 Posts
Discussion Starter · #20 ·
Woohoo! I got the rear motor mounts all designed up and roughly done with PVC and wood, and the front sprocket and swingarm pivot bolt are 4" center to center.

Seriously so excited to get my rear motor mount bracket done and posted up on here, it is gonna look so sexy! :party-smiley::party-smiley:
Once the rear motor mounts are done then I'll go back to figuring out the front end/cradle section, but one step at time!
 
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