The DDPP (Definitive DR Prep Project)
 

PREPS FOR LONG HAUL

– This is just collation of members' posts collected into one place, in an ordered way - to make things easier to find

– Specific to DR650, but most things generic for all bikes

| NOTE: || Its a work in progress - || if you've got something to add, or I've made an error, || please comment. I will update as and when. |

• Air filter socks. Slips over standard filter. Replace when dirty. Reduces frequency of filter replacement. [Frank]

• Engrave the inside of the valve covers with the clearence values. [Frank]

• Lower chain guide
- make out of multiple bits of chopping board. Rotate when worn - extends life. swap with outer bits so have built in 'spares' [Frank]

• Replace headlight bulbs for brighter - more here http://www.horizonsunlimited.com/hub...741#post146788

– I'm still working on this section, since there is so many options and opinions all over. Perhaps just leave it for the 'Equipment Forum', HOWEVER, Peli Cases seems to be the fashion accessory of choice on the DR forum [Molly Dog, Fat Chance, Lone Rider, mrdnd, Mountainman]

**Dont forget the feather pillows**

As promised...
 

This is a DRAFT - so please add comments, corrections etc.

Its a bit crude, since I can't use HTML --- so much for prettying things up.. :(

ALSO - we're only allowed 15000 characters, and so I had to remove sections...(already 23456 long) :confused1:

WANT to post it in ONE place cos thats the whole point.

ANY IDEAS.. moderators maybe?

Belongs here
 

Just my couple of pennies worth
 

Hello Mollydog,
I believe your right; I was kind of hoping that a moderator (maybe Impasto will get such rights?!) would pick up on this and transfer very useful information that does not time expire, into that library over to the left - actually that library is looking sort of "tired" and quite a bit out of date. I must be one of those sad people who look over there occasionally!!

Sorry for that very short post of mine (tired of typing!), but it does seem quite a waste when really useful info disappears into the welter of other threads; stickies would be a part-solution, but if every bit of useful info was made into a sticky then the threads would be full of them and, potentially, negate their value:-
Sticky DR
Sticky DL650
Sticky DL1000
Sticky DRZ etc etc

Another example is your maintenance thread which is of the same ilk, and would be very valuable as a checklist over there on the left (that sounds like a political slogan!!). Even airline pilots know the value of a checklist.

I agree that folk will come to the HUBB first which is why, if the data on the left is up to date and relevant, we/you could refer to there and save a bit of typing ( IIRC a while ago you were getting a bit fed up with answering the same questions over and over?).

The saving grace in all of this is the search function within the HUBB and Grant J has pointed out in the past that no post is ever deleted - excellent!

Yep, from your last paragraph, Impasto should be a moderator - gets my vote!!!:rolleyes2:

Cheers,

Multi-stickies?
 

Hi Guys and Guyesses. I'm conferring with Grant over this one. It seems to me that, like Walkabout says, it could potentially end with a sticky for every model. But is that a bad thing? I also think it should be pointed out that it is still possible to do some pretty serious traveling on a very standard bike. I would hate to see lots of people turned off getting out there if they think that they will need to spend a whole lot more money. The DR650 is a good bike, off the showroom floor. How many mods to people think are ABSOLUTE must-does?

Regards

Nigel in NZ

GREAT post impasto!

And it is something I've been getting closer to for years - literally - and we're now almost there!

I was hoping to have it fully sorted today, but no such luck.

Take a look at the top of the left menu - you'll see under your name, "Create content" click and you'll get 1 item at the moment "
equipment review Review anything you've used on your travels" There will soon be something else - "bike prep" or some such. It will be to create a page like:

http://www.horizonsunlimited.com/tech/suzuki/dr650prep

NOTE: You MIGHT not be able to access this at the moment - we ran into difficulties with the access and edit rights - but we hope to have it working very soon. Once it's sorted it will enable us to do lots more too. :)

which is of course the DR page - I just need to sort permissions so Impasto can edit the page. At the bottom you'll see comments - click and it takes you to the HUBB thread already started. :) So the idea is that the first post in the thread will be a link to the whole page - and the page links to the thread for comments. Almost done, give me a day or two to tweak the details.

Grant

Sounds good!
 

That's an important point - there is always more than one way of skinning any cat, usually there are quite a few.

Grant's solution sounds good - A kind of FAQs (frequently asked questions) perhaps is the analogy, in this case for specific bikes.
Perhaps this new content can reflect clear fact and the HUBB can be used for expressions of opinion & asking questions?

Hmm, never seen a DR with one of those.

Mine does not have one either! ..
Think that would be for a bmw oilhead...

--------
My thoughts - genric sould be on a generic FAQ .. not specific .. so 'we' all know it applies to all bikes .. that way anyone with an model not covered would still have a guide.

-----------------
On my DR I've about the same weight as a standard bike .. removed some stuff .. added others .. like a bash plate .. with spare F&R brake pads ...

-------------------
One of the things about the long haul .. carrying the 'consumables' and servicing .

I carry a spare chain roller - bolt on to the right side where the pillion peg mounts .. hides nicely there. The lower chain guide - make out of kitchen chopping board ... multiple bits so the waring bits can be rotated upside down - extending their life .. and swaped with the outer bits so having built in 'spares'. Not found a good soluition for the swing arm chain protector ..

The sealing crush washers for drain/timing plugs fit nicely behind the frame rubber plugs ..

Servicing of the air filter is too frequent .. I'm using air filter scoks .. go over the standard air filter - pull the dirty one off and put on a clean one .. 3 off these should get me to the next engine oil change where I do all the air filters together, and change the engine oil ... rather get dirty once than 4 times..
------

Lookin forward to it... I'm all excited! I thought RIDING the bike was the funnest part! :thumbup1:

Thanks for your thoughts guys...

About generic vs specific

We could defintely include other suzuki's - it would be no prob to add to the entry which model an entry is specific to. However - a non-suzuki list doesn't get my vote.

As we've already seen -- just by adding one non-suzi related item, I wasted an entire day, trying to find an alternator belt for my DR. (kidding, by the way)

The list was originally inspired by the WEALTH of information supplied by in particular mollydog and added to by other posters - its a shame to lose such model specific info in a mountain of threads. If there are other peeps with other manufacturers who have so much to add - it would be good to collect them too.

A generic list wouldn't fulfil my needs. And I always get my needs fulfilled, damn it. :rolleyes2:



Lets suck it and see. It may be that the list becomes unwieldly because there is too much - then we split it into different suzuki models.

For now (until I change my mind and decide do transafrica on my KTM Duke II ), you have my undivided attention and I would gladly look after the suzi list.:tongue2:

Ha .. try making GPS maps for strange places... days of fun... to save hours of being lost ..

Preping the bike is mostly sitting looking at it and thinking about the "what ifs" that too can be 'fun'. Most of the best mods take little money - just thought .. like engraving the inside of the valve covers with the clearence values .. saves looking them up, carring them around .. and they are there for all time. And that would be a generic mod .. fits all bikes/cars...

ooh. very clever. definitely going in. and reminded me of reading somewhere that you should find out before departure where your frame/chassis/engine numbers are.

And also note the main bearing numbers (steering head bearings, wheel bearings, chain idler etc), NOT the spare part number from the manufacture, so you can order generic bearings on the road. My F650 needed new steering head bearings. I rang the dealer who quoted me NZ$130 for a kit, then cleaned up one bearing to take to make sure of a match. On the bearing I found a Niachi bearing number and got a pair from the Niachi agent for NZ$26. I was careful with taking out the dust covers and did the job for 1/5 the price.

Regards

Nigel in NZ

The standard chain idler is a plain bearing - has no numbers. Probably only avalible from Suzi .. the 'better' one does have bearings .. but they are small and may not be as easy as the larger bearings to find.

They should all be noted down .. The ones in the swing arm and suspension linkages too ... if they have numbers .. if not then the suzi part number.. or an alternative..

A link or two to online dr parts fish would be good

Alpha Sports - Suzuki Motorcycle Parts Catalog

Motogrid | Honda OEM Parts | Kawasaki OEM Parts | Suzuki OEM Parts | Yamaha OEM Parts

And may be those after market bits
KienTech Engineering
Chain Gang

Those stone filters will stop sticks and stones, but not gnat hair.
Also, a larger filter will allow greater flow, less resistance.

You will have to learn your own way about when to flip over to reserve on your bike. With the translucent tank this is easy to gauge, and I will sometimes flip to reserve even with a couple of gallons remaining because I know where my next fuel stop will be.

It's a Fysicks thing...:)
Apple on the head kinda deal....whatever his name was...

The carb inlet is below the tank, but the carb inlet tube does rise in the NW direction. Some people have put the tube in a vise and gently, but forceably 'encouraged' it to go more southward.

It'll all work out, you know your sht.

BTW, CC rocked.

May your bottles of Carta Blanca be lathered in frost.....

I just use indelible felt pen and write on the outside of the engine. Also tyre pressures.

Nor grass seeds - Shade cloth will. Also causes less air to flow. Fly wire will stop most of it .. Both these need a stronger 'filter' for rocks, sticks.


I find indelible felt pen fades over time. Say a year in sunshiine.

Howdy Frank,

I carry 3 feelers with me on the DR: a 4, an 8 and a fat one that mates with the thin 4 for plugs. There's no need for others.

Yes. Who wants to clean a carb on the side of the road with no shoulder when it's raining and dark, and in inhospitible places just because you allowed crap to reach your carb? Plan for the worse, of course.

Ehm. Sorry guys. :blushing: Can someone translate into stupid speak?

Should I be paying attention?

Do I add anything to my list. Or do I delete something? Or do I wait for a conclusion to something.

If so - er.. what?

Gravity sucks
 

No liquid can flow uphill may be the problem, although I seem to recall that mercury has some strange properties - but I digress.

"Uphill" includes the resistance of any liquid to flow through a constricted pipe and the "natural" resistance of the friction of the fluid when it is moving (even when it is moving more slowly than you would like): so the potential is for an airlock to develop.

I can't see how a larger loop of hose would help; it would if there is a definite kink in the existing hose, but otherwise it is just adding more flow resistance inside the longer length of tube.

A fuel pump would be the answer.

Good travelling Mollydog,

Fit a fuel filter is the basic, generic, translation!! After that, it is a case of which one works best.
No charge for the translation service!! :rolleyes2:
BTW, always best to wait for a conclusion.

Oh. phew. Thank you!

Fuel flow
 

Hi all,
First post on a BB.

To solve your fuel delivery problem, a simple, very reliable, vacuum operated diaphram fuel pump will fix it. It is the pump fitted to DR750, XT660 Tenere, XTZ750 Super Tenere (I have all three, plus more). All these bikes have tanks which are below carb level. I run a steel mesh filter before the pump (high flow rate, filters larger bits), and a paper filter after the pump (no little bits make it to the carbs). Very low output pressure, so won't force the needle off the seat.

I haven't tried this (yet), but if anyone wanted a super strong DR with a difference, a DR650 motor in a DR750 frame would be capable. The DR750 frame has bigger tubes everywhere (but doesn't seem to weigh much more; I have the two frames side-by-side). I'm currently fitting a later DR front end (43 mm forks with adjustable preload/damping) and alloy swingarm to the 750 frame.

Does anyone (with an engineering background or tested knowledge) know the pros/cons of tapered roller bearings versus ball bearings in the steering head? e.g. friction versus load capacity, wear, etc.

Thanks in advance....

The advantage of a roller bearing is the load is spread over a larger area than ball bearings. For head bearings this means they shoud last longer and require less adjustments than ball bearing.

These typically fail due to impact damage - forming a line where the roller contacts the surfaces. If you were to use a ball bearing you would have a point contact - much higher loading on the reduced area = highter failure rate.

Same kind of pump fitted to Honda ATs, KTM950 ... they do fail...

------
The 'vacume system' on later model DRs operates the standard fuel cock. If you put on anotehr fuel tank you probably don't have it ..

One of the nice things about the DR is that it's blessed with no fuel pump.

Wow great stuff
 

Just a short note to say thanks for such a great effort collating all this info to help other DR riders. Are the techie tips applicable to all models of DR650?Thanks a lot, Jenny64.

I'm on it!
 

Well, despite appearances (XT Girl and all that) I have NOT sold the DR600 and my loyalty will always be with it!

Sooo -- I will take on board your suggestions Mollydog -- i like the idea of pictures.. and products.. and keep going with this.

Watch this space.

M

Prepping a pair of DR650's - useful link here
 

Hi everyone

After reading this post and many others through ADV etc, I recently finished prepping 2 DR650's for the big SOuth America trip in 2009.

the trip is on THE WRONG WAY DOWN

but if you just want to have a look at the prep and parts purchased for the bike to do it, you can go to:

DR650prep

Hope this is of use to any of you thinking of doing the same! Happy travels

I will add a post match commentary once finsihed on bits I wish I had done and bits I shouldn't have bothered with.

Cheers,
Barney

I'm installing a safari tank over the holidays, thanks for the heat resistance tubing tip.
Rellay nice website you have as well.:thumbup1:

You may have seen my DR650 prep thread? Too bad, it's deleted!
:scooter::scooter::thumbup1:

Stuck for parts and can't find the correct forum
 

Hi, my name is Bert and I am from sunny?!?! Glasgow in Scotland . I am in need of a camshaft and both cam rocker arms for mr 1990/91 dr650rs but can't seem to find a source. I think( know ) this isn't the correct part to postthis but I am round the world ready after I get these parts. All paperwork and prep done , offthrough middle east to vietnam and back through Russia and home. Any ideas where I can getthese parts would be more than appreciated. Cheers. Bert

Strange, can your local Suzi dealer not order them? Failing that try contacting Stefan at Hessler RT Online-Shop . Email stefan {at} hessler-motorsport dot de He's the self-proclaimed DR expert in Germany and I have bought many bits off him. Customs and postage might be a killer, though.

Cheers,
Peter.

Cheers good sir, topsite.
I can see the budget vanishing rapidly. ;)
Bert

corbin seat
 

what is a Corbin seat and its purpose ???

There's a good explanation here: Corbin Motorcycle Seats & Accessories | How it Works! | 800-538-7035

Comfort and weight saving, I think is the predominant reason for using it.

Xtgirl,

While the Corbin Seat is much more comfortable it probably weighs 3 times as much as the stock seat!
Not nitpicking but I don't think you would want to spread bad info!

When I bought my stock DR650SE, I was nearly in tears during my first long day (500kms), it was SO uncomfortable. I'm about 6'1" and the seat totally killed my ass, my lower back was aching etc. I thought about selling it after that ride!

After a bit of thought, I put on high Renthal bars to solve the sore back issue, Corbin seat which is a lot wider than the original and the 20L IMS tank which gives an easy 350ish kms before you really need to fill up again (mine usually got 20kms/L), a huge improvement over the original 13L tank. Plus a cheap 2nd hand $20 bash plate. Sorted. I could then ride long days with no problems at all. The Corbin isn't so much about weight as I think it is a bit heavier than the original however the DR is so much lighter than my 1150GS so I didn't really notice.

One point to note if you're using Andy Strapz panniers is than one of the straps goes across the top of the seat and you can end up partly sitting on it which gets pretty uncomfortable on a long day/high temps however a bit of sheepskin would no doubt sort this.

Acerbis offers a 6.6 gallon fuel tank for '92 and older 1992-1995 DRs. I wanted more capacity than the IMS 5 gallon model, and couldn't see spending $550 for the Aqualine 8 gallon model.

First, the physical differences between the stock tank and the Acerbis model:
http://www.schoolbushomestead.com/ph...92_7WhRo-M.jpghttp://seanf.smugmug.com/Not-about-t...92_7WhRo-M.jpg

http://www.schoolbushomestead.com/ph...56_LBxxx-M.jpg


We needed a few modifications to make it fit my 2008 model.

The turn signals are in the way of the tank well before full-lock of the handlebars, so I switched the mounting brackets to opposite sides, and then reversed them. This moved the lights up and forward a bit.
http://seanf.smugmug.com/Not-about-t...61_goTNW-M.jpg
http://www.schoolbushomestead.com/ph...61_goTNW-M.jpg

Spacers had to me made for the support bolt that runs across the frame tube. It helps to have a friend with a lathe who isn't afraid to use it.
http://seanf.smugmug.com/Not-about-t...37_QXvDy-M.jpg
http://www.schoolbushomestead.com/ph...37_QXvDy-M.jpg

http://www.schoolbushomestead.com/ph...73_NoB93-M.jpg
The spacers replaced a pile of washers and other kludgy bits.
http://www.schoolbushomestead.com/ph...76_CcbRi-M.jpghttp://seanf.smugmug.com/Not-about-t...76_CcbRi-M.jpg

Oil cooler and crash guard: The oil cooler has to move forward a few inches. The mounting tab was easily bent by hand. The cooler guard will take more work.

Oil cooler moved forward slightly; also cut out a section of the oil cooler guard.
http://www.schoolbushomestead.com/ph...67_DF7Dz-M.jpghttp://seanf.smugmug.com/Not-about-t...39_BP9pH-M.jpg

Fortunately, 1/2" mild steel tubing fits perfectly inside the tubing used for the stock guard. Using a tubing cutter and a bender, I pieced together a new bracket that not only fits around the tank, but provides a little more coverage than the stocker.
Mock-up:
http://www.schoolbushomestead.com/No...03_QmEJ8-M.jpghttp://seanf.smugmug.com/Not-about-t...03_QmEJ8-M.jpg

Another angle:
http://www.schoolbushomestead.com/No...26_WnmKb-M.jpghttp://seanf.smugmug.com/Not-about-t...26_WnmKb-M.jpg

Brazed and painted (sadly, my skills are lacking in both areas):
http://www.schoolbushomestead.com/No...28_qiXmw-M.jpghttp://seanf.smugmug.com/Not-about-t...28_qiXmw-M.jpg

The angle of the tank doesn't quite match the angle of the seat, so I cut off the forward section of the pan:
http://www.schoolbushomestead.com/No...89_PgiAt-M.jpghttp://seanf.smugmug.com/Not-about-t...89_PgiAt-M.jpg

...and the rear flange of the Acerbis tank is quite a bit thicker than the stocker -- so some tough love with a Dremel tool and a heat gun brings it into shape:
http://www.schoolbushomestead.com/No...58_pMffk-M.jpg
(NOTE: Yes, that is a hole in the center of the rear flange of the tank [above]. We had a discussion about whether that flange was solid or hollow, because if solid it would open up more mounting possibilities. Turns out -- it's hollow. The hole was a test and easily patched.)

And now the seat foam gets some attention. After this pic was taken I leveled off the front of the foam and cleaned up the sides up front. An angle grinder used LIGHTLY makes a great foam sculpting tool.
http://www.schoolbushomestead.com/No...53_SMqdh-M.jpghttp://seanf.smugmug.com/Not-about-t...53_SMqdh-M.jpg

The Acerbis tank has two petcocks, and comes with a length of fuel hose and a cheesy plastic tee -- I replaced it with a barbed brass tee.

Result
http://www.schoolbushomestead.com/No...79_YjXjk-M.jpghttp://seanf.smugmug.com/Not-about-t...79_YjXjk-M.jpg

http://seanf.smugmug.com/Not-about-t...45_jVu6q-M.jpg

http://www.schoolbushomestead.com/No...45_jVu6q-M.jpg
Cheers,
Sean

Nice, vvveeerrryyy nice.

Cheers bloke,

Nigel in NZ

I my opinion do NOT do the carburetor mods. Just enlarge the air intake for high altitude cruising.
The carburetor mods require BOTH a high flow exhaust and a high flow airfilter like the K&N filter to work properly.

The K&N airfilter is NOT suitable for serious offroad - high dust type riding as it is quite a coarse filter.

I have the carburetor mods with normal airfilter and stock exhaust and the fuel consumsion is about 25% more than my buddys bike which is stock.

Stock jetting is suitable for up to at least 5000m and in fact I would not worry about any re-jetting while riding on this planet.

Just my 2 bobs worth (and advise is for touring and NOT racing :-)

Also the DR is one of the most suitable touring bikes if you want to have some offroad fun.

K