Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Suzuki Tech

Suzuki Tech Suzuki Tech Forum - For Questions specific and of interest to Suzuki riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 29 Apr 2010
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2003
Location: Oxford, UK
Posts: 1,028
DRZ pannier frames:

Just finished building these pannier frames for my partners DRZ in preparation for her trip to South America starting mid-August:









Few more here: DRZ PANNIER FRAMES - Steve's Photos

Started with the Suzuki rear rack and a pair of Givi pannier racks for an airhead GS:



Once I removed all the bracketry, I wrapped some 3mm x 25mm steel bar around the 5 litre fuel can before welding. Once I'd mounted the right hand loop, I lined up the left hand loop before mounting it. I could have kept the width down by locating the frames more rearwards but wanted to keep the centre of the frames in line with the rear wheel spindle. The two main mounts on each side are made from steel tube, 16mm OD with a 1.5mm wall thickness with 10mm stainless capheads passing through, secured with Nylocs.
I then turned down some steel bar to match the internal diameter of the 16mm tube & then drilled 8mm holes through. In to 20mm sections of tube, I welded 5mm lengths of drill steel bar. Four of these provided the mountings for the mounts on the footpegs & the frame on to which I'd already welded a 6mm thick lug. By mounting to the frame itself, I've used the pannier frames to brace the subframe. Stainless 8mm capheads slid easily in to the front mounts.

I also incorporated a Tooltube for Tyre Levers etc, a bolt through the cap plus an O'ring will prevent the cap coming loose. The final part was the rear brace, 16mm tube used once again in conjunction with 10mm stainless capheads.

The Givi frames cost £50 & I reckon I spent another £50 on 3 metres of steel tube, flat bar, welding gas & wire plus stainless bolts. So far I've spent between 30 & 35 hours on them, they still need to be removed, blasted & powdercoated. They'll be fitted with waterproof Ortlieb panniers. Total width is very slightly wider than I'd like but the weight distribution is much better for it. She'll be riding away from the cities, mainly in Argentina & Chile so width is not that big a deal as she won't be filtering through heavy traffic.

We'll be fitting blue bodywork from the other DRZ plus a Clarke tank, rad guards, Wolfman tankpanniers & tankbag plus a front mudguard brace. I've already fitted Talon lowering links & 'bar risers to allow the forks to be pushed through by 20mm. Rear preload is on max at present which is why it doesn't look that low. Once new chain & sprockets, pads & more suitable tyres are fitted, it will be pretty much ready to go.

Thanks to Louisdut for the idea for the additional can.
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #2  
Old 29 Apr 2010
Mickey D's Avatar
Moderated Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: California
Posts: 514
Great prep on the DRZ! Five Stars!

I have seen these Happy Trails racks used with some success.

Suzuki DRZ400S Original Side Racks - KLR650 & Adventure Touring Motorcycle Luggage and Aluminum Panniers

They tuck in a bit closer but won't allow for the inboard storage you've devised. Sounds like she'll be well loaded for a year or
two camping trip! Safe riding y suerte!
Reply With Quote
  #3  
Old 29 Apr 2010
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,430
EXCELLENT WORK !!!!

Much better than my 20 minute effort !!

I don't know why I never thought of using donor frames !
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #4  
Old 29 Apr 2010
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2003
Location: Oxford, UK
Posts: 1,028
Thanks for the compliments.

The Happy Trails look as if they only have two mounting points per side:



I also don't like the fact that the rear of each frame is unsupported i.e. lacks a cross-brace. Also made from 0.5" tube (12mm) where most other frames are 15mm minimum.

My welding leaves a lot to be desired IMO, I don't practice enough to get good at it. If in doubt, I pile the weld on..... All welding was done with a cheap Clarke 100amp MiG welder that I bought nearly new about 12 years ago. Now thinking of investing in a tube bender & a cheap TiG welder that will allow me to do steel, stainless & ally welding. I bent the tubes for the DRZ frames in a vice around mt MiG welders gas bottle.
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #5  
Old 29 Apr 2010
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,430
Steve !! I just noticed that you havn't fitted case savers to the clutch and generator covers ! (not that I can tell anyway)

This is a MUST with the DRZ400. The cases are very very thin. In a topple, the brake or gear pedals usually smash through them.

Available widely for about £20-£30


Are you fitting a bigger tank too ????

BTW, the rads are pretty weak too. Neil (my riding partner) has an Aqualine tank and dropped his bike last week and the seams split on the rad. UNIBIKER make GREAT guards for the DRZ (see on my blog below).

I welded a 3" square onto my side stand too. My DRZ loved to sink into even the hardest of dirt.

I hope i'm not trying to teach my granny how to suck eggs here, you obviously have a talent for prep !
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #6  
Old 29 Apr 2010
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2003
Location: Oxford, UK
Posts: 1,028
Thanks Ted, well spotted but......

Awaiting delivery of rad guards.

I'm making case protectors out of 2.5mm thick ally sheet as I've done on my 950SE, already holed a clutch cover when the brake pedal went through it.

I'll either make another case saver around the front sprocket out of 6mm steel or use the similar one I've made previously that's fitted on the other DRZ. Ela holed an engine last November when a chain snapped, left a 25 x 5 mm vertical hole in the clutch arm/shaft housing. I cleaned it out, shaped some ally to suit & had a friend weld straight over the top, worked a treat at no cost apart from new chain, sprockets, rear tyre (soaked in oil) and several oil flushes & filters, wish I'd taken a pic of the damage before & after the repair.

Got a large (14.8 litres?) Clarke tank in blue in the garage awaiting fitment, will be fitted along with the rest of the blue bodywork from the other bike in due course.

Re: sidestand: not making any mods until the bike's fully loaded as I may need to shorten the stand a little, if so, this is when I'll increase the footprint.

Did you use a standard shock or a heavier spring or re-valve etc?
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #7  
Old 30 Apr 2010
Mickey D's Avatar
Moderated Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: California
Posts: 514
Quote:
Originally Posted by Steve Pickford View Post
Thanks for the compliments. The Happy Trails look as if they only have two mounting points per side:



I also don't like the fact that the rear of each frame is unsupported i.e. lacks a cross-brace. Also made from 0.5" tube (12mm) where most other frames are 15mm minimum.
My welding leaves a lot to be desired IMO, I don't practice enough to get good at it. If in doubt, I pile the weld on..... All welding was done with a cheap Clarke 100amp MiG welder that I bought nearly new about 12 years ago. Now thinking of investing in a tube bender & a cheap TiG welder that will allow me to do steel, stainless & ally welding. I bent the tubes for the DRZ frames in a vice around mt MiG welders gas bottle.
I'm no welding expert but I thought your work looked pretty damn good! Main thing is that it don't crack!
For soft bags its the cross straps across the seat that is really supporting all the weight. In my experience with soft bags, the racks are mostly there to attach to in order to keep bags from flopping about, out of the rear wheel and off the pipe .... most the stress is on the cross straps hung over the seat & rear rack.

I like the tool tube idea. Good to keep heavy things low and central, never behind the rear axle. Happy Trails racks put the bags well forward.

Quote:
Originally Posted by *Touring Ted* View Post
Steve !! I just noticed that you havn't fitted case savers to the clutch and generator covers ! (not that I can tell anyway)
This is a MUST with the DRZ400. The cases are very very thin. In a topple, the brake or gear pedals usually smash through them.
Available widely for about £20-£30
BTW, the rads are pretty weak too. Neil (my riding partner) has an Aqualine tank and dropped his bike last week and the seams split on the rad. UNIBIKER make GREAT guards for the DRZ (see on my blog below).
Plus One on Ted's suggestion. I punched a nice hole in my left side case. Remember, covers are Magnesium! I used Chewing Gum to plug the hole! The aftermarket covers a definite must. I also bent my Rads (My DRZ-E was my dirt bike) but never busted one open. Guards are well advised, pricey bastards though. Mine could do about 60 mpg
(US gallons) (in cruise, non dirt mode).
Reply With Quote
  #8  
Old 30 Apr 2010
gixxer.rob's Avatar
Registered Users
Veteran HUBBer
 
Join Date: Mar 2008
Location: Back in Melb
Posts: 292
Nice Work

Nice work and description Steve, be sure to post a picture of the finished bike. I and many others i'm sure, would love to see it.
Reply With Quote
  #9  
Old 30 Apr 2010
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2003
Location: Oxford, UK
Posts: 1,028
Pics of the finished item will be posted in due course.

Re: rad guards, when I first looked, they seemed to be quite expensive until I found this guy on Ebay:

SUZUKI SMS RADIATOR GUARDS DRZ 400E RMZ 250 on eBay (end time 18-Apr-10 22:05:26 BST)

£40 buy it now price inc. postage. I put in a bid of £30 & won the auction. I know they're intended for a 400E but if they're different, I'll make them fit at that price. They're due to arrive imminently, I'll post if if the fitting is any different to the 400S.

Using Ortleib panniers, I'll thread the closing strap through the small loop welded to the top of each pannier frame. The Ortleibs attach across the seat with 2 x 3" wide velcro straps, I'll also be threading another strap across the seat that threads through the carrying handles & snaps together.
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #10  
Old 30 Apr 2010
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,430
I'm using the standard shock with 11,000 miles on it.. No leaks or squeaks that I can see.

I'll wind up the preload just a touch. I road tested it and it was fine !

I've got to the point where I dont want to spend anymore money.. Enough is enough !!
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #11  
Old 1 May 2010
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2003
Location: Oxford, UK
Posts: 1,028
My only gripe with the standard shock is that it's a PITA to adjust the preload. Anyone know of a reasonably priced aftermarket shock that comes with a (remote?) hydraulic preload adjuster?
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #12  
Old 2 May 2010
Mickey D's Avatar
Moderated Users
Veteran HUBBer
 
Join Date: Jan 2010
Location: California
Posts: 514
Most modern aftermarket shocks for the DR400S can be ordered with the option of having a remote pre-load adjuster: Wilburs, WP, Elka, Ohlins, Penske all offer remote preload on many of their shocks for most bikes. Costs extra of course.

I have an older (10 years) Ohlins on my DR650, no remote preload adjustment. I don't ride two up so pretty much, once it has been set, I'm done.

It does have easily accessed compression and rebound adjustments ... and they actually work! One thing I really like is the RIDE HEIGHT adjuster on my Ohlins. Very handy and easy to raise or lower rear ride height by about 1 1/2 Inch. There are a number of reasons why a ride height adjustment is good to have. I am pretty sure ALL the above companies offer this as well.

If it were me, I'd have the stock KYB item re-valved and re-sprung and set up to appropriate weight/load and riding style, set preload (manually) and leave it.

A local suspension company (Aftershocks) modified our DRZ-E suspension this way and transformed the handling of the bike. (for enduro riding and Baja)
Reply With Quote
  #13  
Old 2 May 2010
Registered Users
Veteran HUBBer
 
Join Date: Nov 2008
Location: poole dorset
Posts: 152
Hi Steve rack looks great. Draper have got tig welders on offer at the mo, stock no 43954 looks pretty good for the money £273.90
Cheers Jim
Reply With Quote
  #14  
Old 3 May 2010
Steve Pickford's Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2003
Location: Oxford, UK
Posts: 1,028
Thanks Jim, the cheaper TiG's tend to be only capable of welding steel. I'm thinking of spending £500+ on one that's capable of welding aluminium.
__________________
My photos: www.possu.smugmug.com
Reply With Quote
  #15  
Old 16 May 2010
Registered Users
New on the HUBB
 
Join Date: Jun 2006
Posts: 13
DRZ setup for overland travel

A couple of years ago I was setting up a DRZ for an ATW trip. I was asked to write a note on my preparations. Here the link to ADVrider. Maybe this might be of some help

Setting up a DRZ for ATW trip - ADVrider
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
R100GS pannier frames wanted peachface TRAVEL Equipment for Sale / Wanted 2 13 May 2009 23:41
KLR 650 DIY Fibreglass Pannier Boxes and Frames tenere_rider Kawasaki 0 14 Sep 2008 15:52
pannier frames for AT RD04? hurcomb Honda Tech 1 28 Jul 2008 12:00
Transalp Pannier Frames Wanted Spokes TRAVEL Equipment for Sale / Wanted 0 21 May 2005 18:02
WANTED: TOURATECH PANNIER FRAMES FOR R100GS-PD Paul Narramore TRAVEL Equipment for Sale / Wanted 0 12 Feb 2005 03:49

 
 


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.


Renedian Adventures


Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!


What turns you on to motorcycle travel?


Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!


New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.


Books & DVDs

amazon

All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.


Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!




All times are GMT +1. The time now is 02:30.