What should I do first? I am looking for a new chain roller, a rear swing arm skid plate, end cap, heel guards(-broken), who makes the best and where can I get them. I am in Canada. What other mods should I look at? Port the intake, cdi box?? What is this about clamping the intake hose? When do the shocks get rebuilt? What kind of oil does it use, as in grade, no manual yet. Is there a owner, repair and race cd like ski-doo has for there sleds or do I have to buy them seperate. Is there a race manual? Any other tip and tricks I should know?

 

First set the sag of your bike. Next pipe and jet the thing. Third Cdi box. As for parts. Check ebay they always have someone selling the stock pieces your looking for. Tm design works sells the chain roller but I have a less expensive solution for buying the 30 chain roller. Go to sports store and find a skateboard wheel thats similar size to the chain roller. I bought a pack of four wheels at Academy for 8 dollars and they last longer than the chain roller.

 

Get an aftermarket chain roller, or use a skateboard wheel & 4 bearings. Take a good look at Pro-Armor for the skid plate, and also consider a chassis skid plate as well. I'm quite happy with my Mr. Horsepower billet end cap, as long as you don't have to worry about sound regulations you should be OK. (It doesn't come with a spark arrester, though you can make out out of most any good metal screen material.) I also had the intake ported on both machines - it is DEFINATELY worth the price I paid. If you have $400-ish (USD) to spend on a CDI then take a look at the Vortex CDI. The tapered rubber boot that leads from the air filter to the carburetor should have 2 - 3 hose clamps clamped around it just snug. This keeps it round and wide open under high RPM. I'm using Maxima oil, I forget what grade though. There is a book manual as well as a CD version of the manual. I don't think that there is a race manual.

On the 2001 you'll want to make sure that your cooling fan still works - if it does, it will probably break. If it does not, then you get to decide how you want to fix it.

1. If you have time and are a good welder, you can fabricate a new mounting setup just like the newer DS650s. (I think I'm one of the only people with this setup.)
2. Chuck the dead fan in the garbage & add a few other items to cool the engine. (in line coolers, 'cooler' coolant, radiator shrouds, etc..)
3. Keep replacing the fan as it breaks for either $70 or $140 / each depending on where you buy it.

I don't think you can rebuild the facotry shocks, most people opt to buy some nice aftermarket ones if they have the cash.

Also the castor (I think) is said to be too extreme on the front of 00 - 01 DS650s and many people have bought aftermarket upper A-Arm kits to resolve this issue.

 

Welcome too the club[img]i/expressions/face-icon-small-happy.gif[/img]

 

I live on a farm so noise is not a concern, except for my own ears. I am going to drive this thing across my fields that I would discribe as wash board for the trail riders. What is the best damping set up for fast 6" repeating bumps? This is going to be too much fun[img]i/expressions/face-icon-small-smile.gif[/img]

 

Sounds like you need to set up your DS like mine... I know it works well for tearing across fields!

10-40 oil. No synthetics, unless specifically for wet clutches.

Definately look at getting an end cap.

Go ahead and put some hose clamps on the air tube.

Skateboard wheel, chain roller, whatever, they all work the same, so choose your price and color.

My PRM skid plate is still as solid as the day I bolted it on.

I made my own heelguards. If you have time and access to some sheetmetal working tools, it's the way to go. Plain ol' sheet aluminum can become some good looking heelguards.

Intake porting is probably my next mod.

The rear shock is rebuildable. Mine was rebuilt just before I got my DS.

I don't know anything about suspension setup.

If yours still has the stock tires, ditch them. I would have done that by now, but I spent my tire fund on paddles.

If you like riding wheelies, order a new rear bumper now. The stocker doesn't last long on hard dirt. [img]i/expressions/face-icon-small-blush.gif[/img]

 

Call tcs for the shock rebuild. They can set you up with new fronts and rebuild the rear to however you want to ride. Expensive, but the difference is amazing. Buy the service manual from a dealer, or there is a cd version on ebay all the time. Oil- Search for old posts on the topic, there are a lot of them. I run the factory synthetic oil. Most people think this is good oil, but it is very expensive. Most people run 10-40 or 5-40 oil in the winter and everything from 20-50 to straight 50 weight when it is hot.

Keep asking and we'll keep answering.

Justin