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PostPosted: Mon Jun 06, 2011 2:02 pm 
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Hi, my name is Ton, 35 years, sales manager for a machine building company and passionate about bike building/modifying which I do in my small but well equipped garage.

I currently own about 6,5 bikes of which one is a bit of a mongrel; a Honda FT500 with a DR600/650 engine. The previous owner said it dyno'd at 60hp at the rear wheel so I thought you guys might be interested in the set-up.

Well, and this is where me joining this forum comes in, I don't have the slightest idea about the set-up. Let me try to explain: It seems that the bottom end is from a DR600 (number starts with N401), using the left engine cover of a 1997 DR650 as it also covers a non-existent starter motor... The barrel is a 640cc unit of a 19?? DR650. It has a cut-out in the cooling fins for some non-existent tube. The head is of a 19?? DR650 and has 2 decompression systems, one on the left connecting to the kick starter, and one on the right connecting to the manual lever at the handle bar. I also got a spare DR600 engine with it with the same set-up, why would it have 2 decompression systems?

According to the previous owner, it has a ported head, hot cam, high compression forged piston, etc etc. It does have a very high compression, without decompression, it is impossible to crank with the kick start.

Some pics:
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PostPosted: Mon Jun 06, 2011 6:21 pm 
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Hmmm... I really don't know what to say... except thats a bunch of horsepower.


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PostPosted: Tue Jun 07, 2011 12:03 pm 
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todztoyz wrote:
Hmmm... I really don't know what to say... except thats a bunch of horsepower.


No worries, me neither :biggrin:

The plan is to take the bike apart, clean up the frame and engine to the bare necessities and make it into a full blown dirt track racer with custom aluminum seat and tank, 19" spoke wheels, Maxxis DTR tires etc etc. I might install a different carburettor, maybe a FCR-MX as done before here on the forum. Then dyno the thing to verify the 60 horses and set up the carb.

I am still finishing my latest project, a 100% Wrenchmonkees rip-off :blush: so as soon as I start working on the DRFT650, I'll post my progress here on this forum, that is, if you guys are interested...


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PostPosted: Tue Jun 07, 2011 12:33 pm 
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BeTon wrote:
The plan is to take the bike apart, clean up the frame and engine to the bare necessities and make it into a full blown dirt track racer with custom aluminum seat and tank, 19" spoke wheels, Maxxis DTR tires etc etc. I might install a different carburettor, maybe a FCR-MX as done before here on the forum. Then dyno the thing to verify the 60 horses and set up the carb.

I am still finishing my latest project, a 100% Wrenchmonkees rip-off :blush: so as soon as I start working on the DRFT650, I'll post my progress here on this forum, that is, if you guys are interested...

I'm interested :s_yes

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PostPosted: Tue Jun 07, 2011 2:09 pm 
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+1 That DRFT sounds like a very interesting project.

Welcome Ton! :howdy:

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PostPosted: Tue Jun 07, 2011 7:07 pm 
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BeTon wrote:
... Then dyno the thing to verify the 60 horses and set up the carb. ...

Welcome BeTon!
I got in trouble before when I was suspicious of a guy claiming 132mph on his DR so all i'm going to say is if you have a 60hp DR please share with the rest of us every detail...

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1976 GT550L, 1974 TS400 in bits, ported Zuma scooter w/ expansion chamber.


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PostPosted: Wed Jun 08, 2011 7:25 am 
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That's definetly a 600 motor, same as my 1985 SP 600. Smaller oil cooler than a 650 and on opposite side of motor, spark plugs arrainged different, twin exhaust ports. You will definetly want to hook up the compression release. Mine kicks over pretty easy but when it kicks back man it will make your foot sore if you don't have boots on. Sounds like a wicked set up, you have the tach set up off the cam too never seen that before. I need to look for those parts. Is that a custom header?? Mine runs 2 into 1 but is routed similar to a 650. I have a factory 600 shop manual if u need any specs on the compression release or Anything.

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PostPosted: Wed Jun 08, 2011 8:02 am 
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If that thing really does produce 60 horse power, the fcr-mx will bump it up a little. And also make it get to the 60 horses a lot quicker.

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PostPosted: Thu Jun 09, 2011 4:48 pm 
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Thanks for all the comments! Oke, so it's a 600 engine with the barrel of a 650 (it says 640cc on the side) with a high compression piston, hot cam, so he says.... As the automatic decompression was not working properly, I disconnected it and tried to kickstart it using only the manual lever; pump the kickstart until it's rock hard and impossible to crank, then use the manual lever to get is just passed its full compression, release the lever and give it a kick. Worked for me, and hasn't bit back yet.

As for the 60 horses, I specifically asked him for that and he said he had it dyno'd to set up the carb, airfilter, exhaust and engine set-up. Of course, I didn't get to see the charts.... Anyway, first impression is that is runs pretty nice with lots of power! I do think I need a new clutch, as I pulled it straight through. After that I will put it on the dyno in the current set-up.

Today I ordered some Maxxis DTR1 tires. These are very difficult to get here in Europe, but they just received a new batch from Maxxis, so I ordered them straight away. I think I am going to use DR800 hubs and have them laced up with 19" Excel rims. Tank and seat will be homebuild from aluminum, after I finish my english wheel that is.


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PostPosted: Thu Mar 30, 2017 10:27 am 
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Hi BeTon!!
I'm new to the forum but when I saw your engine my heart bumped!!
With this cylinder you get 667 cc with a std bore 650 sp 46 piston!!!
And if possibile wit the xf 650 head on top (bigger valves, twin carbs....) in a dr 600 frame should be a nice way to kill myself :idea:

To make a long story short, I have to work on my dr 600 engine.
So can you kindly give us some more informations about your project? I'm very intrested in your setup!!
What about the clutch? Someone knows if it's possible to upgrade a dr 600 clutch drum to at least some of the 650? I think that the original clutch won't last long with a 670 pushing aganinst!
If i'm correct there are no difference in the dr 600 650 transmussion chains so the various dr engines must be very similar each other


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