I would read up a bit on the bike before you start doing modifications.

Jesse at Kientech is a good source for DR stuff and has some gooe items for sale and knowledge about jetting and re-springing the bike.

Verle Nelson has owned many bikes, lots of KLR's and DR's. Has done lots of miles on them and has some good set up ideas too. Really knows his stuff, IMO. His page is loaded with very specific info on using various items on the DR. Excellent page.

KienTech Engineering

Suzuki DR650

You can read back through this thread to see some of the things I've done. One thing I intend to buy for my bike is a fork brace. Doesn't need it much when unloaded but needs it when loaded up with gear.

The bike is so simple to work on, you will find it a pleasure to own. Mine has performed well on several long dual sport rides, but in Mexico was not so great
in the dirt due to me overloading the bike. I was carrying 100 lbs (45 kgs) in GIVI hard bags on board plus with 5 gallons of fuel in the IMS tank. Not good. Important to balance suspension when carrying a load to maintain good front to rear balance.

You should plan to play around with the bike a bit. Go ride a NEW stock bike to gain perspective and a baseline for adjustments. IMO, re-jetting is essential. The Dyno-jet kit will not only add power everywhere, it also will still get good fuel economy if set up correctly and the motor will run cooler. It's the needle that makes the difference....it's all in the needle. Took me a while to figure this one out. So open up that airbox and re-jet. The only trade off is you'll have to clean your air filter more often .....or use Filter Skins!

The bike seems to work well with a variety of tires but the stock Trail Wings work really well. The rear T-Wing wears out to quickly but the front tire works well, is very cheap and lastl 10,000 miles.

For long road trips try a Avon Distanzia for a rear tire. I'm using Pirelli Scopions AT's for day to day riding. Any front will be OK on a long ride.

2003 model may have a leaky base gasket. Seal it with silicone. Should hold it.
Staintunes are wonderful but very very pricey....and I seriously doubt it will add much power....if any. My FMF Q2 did not.....but saved 4 kgs. of weight. I sold it.....too loud.

I had hard GIVI luggage on for Mexico and this is where I ran into probs. I've now gone back to soft bags and am down to just 60 lbs. fully loaded for the long haul. Bike handling is night and day better. I have heavy springs, fork brace coming soon. The GIVI bags empty and their racks weighed 26 lbs. So that is a lot of weight for convenience and ruined the handling on the DR.

Good luck. :scooter:

How'd the tool tube work out?
 

Hi Patrick,

Am trying to think of ways to carry tools on my DR since my original toolkit annoyingly disappeared from my bike recently (either stolen or fell off!). Did the pcv tube on the bash plate work as it looks like it might ground out in rough terrain? I have also seen someone use a similar tube in place of the original tool kit so might have a bash at making one that fits in there.

Reliability Report
 

The trigger/pickup coil failed on my DR at 24k miles and change. This same part (new) failed again at 50k miles.
A repeat at near identical miles leads me to believe this may be the expected life of this part.

The trigger/pickup coil on these bikes come as one assembly with the stator. Online parts cost for said assembly is approx $300 usd.

I purchased a spare assembly soon after the first failure and will now be looking for another spare from another low mileage part-out bike.

Just FYI....

Many people here have reported on their DRs and I don't think this has ever come up. Mine has 130000 km and has been under water recently and it's still going. I suggest you start looking at your wiring and the other ignition system components.

I had a similar problem with my Honda CX500 years ago, but there it WAS a known weakness and Honda later modified the ignition system.

I think we have different bikes - model year.
I have limited knowledge on the bike's elec system, but will be learning more soon.

Hmmmm ..... this is certainly of interest to me as well as I approach the magic 24K pick-up coil explosion threshold. I will inquire of local stator experts and see what is up. I may also be able to put this to Suzuki as well.

On Hondas the pick up coil is a separate item, not part of the stator. I can't believe you have to buy the entire stator!

Another bomb in the DR is that do-hickey bolt that comes lose? I can't remember but it's about time to have a look in side and tighten or loc-tit it.
I know there are threads on this on the "big" thread.

By the way, the magazine has had a '96 DR since '96. About a year ago the gear box failed. I thought maybe it was the lose bolt. Happened at 33K miles.
Now more to this story. The bike was fine with the Boss's daughter riding.
Then, about six months before failure the bad son began riding it, which I never new. He is a an evil rider who loves to BANG shifts, power shift and do endless wheelies. A terrible rider, always on the edge of crashing.

So after the "mysterious" failure of the '96 DR, dad buy "Jr." another ..... brand new DR. Now, just a year later, its popping out of 2nd gear. His riding behaviour is the same and the extended warranty (Western) company do not want to pay. They say that if a bike pops out of 2nd it means its been "abused". I say BS. (even though its true in this case! :rofl: but how could they know that?

Anyway, I may be getting some "spare" parts soon. (from the '96) which dad paid to have the cases split. Bolt salad. Ugly. I have not seen it, but not good. I'ts got an Ohlins everyone wants. I want the wheels and forks.

Patrick:mchappy:

Hi Mike,

The PVC pipe has worked out well for tools / travel. On rough rock step ups or hard hits at speed I never hit it. It does foul the handling some (weight)...I think... making steering just a hair slower, bike feels a bit heavier. Or is that my imagination? Try it, it is easy to reverse and not expensive.

One thing I discovered....the DR is VERY sensitive to those who "Fool" with the steering head adjustment. It is VERY easy to get it too tight.....which ruins the bikes handling big time.

So it seems to err just a bit on the loose side is not a bad idea. I pulled mine apart at 13K miles for inspection. Grease was plentiful and CLEAN ...and adjustment was perfect ...oh ...but I could do better!! I was very impressed after stories I had heard about lack of grease. In my brilliance, I decided to "adjust" the head bearings just a **** hair. Bad idea. Even though the bars wagged back and forth freely....the adjuster was TOO tight and the bike would not steer well in high speed esses, sweepers and such. I re-set it and Voila! back to magic DR handling.

Tool Kit
The stock plastic tool kit is actually pretty good. I'm using it now for short trips as I've removed my "long trip" PVC tool holder for now. Mine has never come lose but a bit of silicone or loc-tite on bolts might help. Be sure to remember to close the rubbber door when your done with tools.:( I can get about 75% of my tools in there. The rest go in luggage. Not too bad.

Baja next month for me and the DR with the hooligans. God help me. Will be doing some secret Malcolm trails and other "death to all who enter" routes. I will be buying a lot of Pacifico's for the young bucks to put me upright and haul my bike (and me) over the rocks when needed. :helpsmilie: I am so slow and weak now. Pathetic.

Ultimately I'd like to custom build an Aluminum tool box, form fit to bash plate. Very gradual slope, well integrated, low profile but would hold enough.

Patrick :scooter:

Replied over on Elec Questions - Rectifiers and Coils - ADVrider

Yeah, and as always, your input and knowledge are appreciated.

Problem solving can be both fun and frustrating.

center stands
 

Anyone found a decent center stand that is "in stock" and worth the money yet?

I got one from the states - made in germany (TUV aproved). It places the foot pegs outwards. The chain rubs on the outer side ... the stand has a spot for it to pass but it is too far in .. so I cut a bit out and sealed it off.. still works. It also needs to go a bit further over centre when on the stand - can easily roll off.
Brand? EMS? don't remember.

If it's German, than it must be the SW Motec one. I saw them on DR's when in the EU and they looked pretty good. Never used one.

No one else makes one for the DR650 beyond SW Motec, far as I know.

Patrick:mchappy:

We chose our bikes for different reasons, just as movies appeal to us for different reasons.

The DR, as light as it is, really doesn't need a centerstand, but some people like the convenience it affords, and accept the compromises.

Personally, if I wanted a bike with a centerstand, I'd choose a street bike.

Dual Star do though to keep weight down, I'm planning on using a length of Alu pipe to prop up the other side. Have seen pics of this being done but not tried it myself yet. My $20 2nd hand bash plate is fitted to the peg mounts so i couldn't use a centre stand with it anyway...

DR 650 Centerstand™

Errr is that the one people have ordered ..and never ever got?

I like a centre stand - alows work on the bike without help. I also like a large fuel tank. etc etc.
So most of my bikes as not 'standard'.