RTW Mods: Making DR650 A Long Range Travel Bike

33 replies to this topic
  • Rob_G

Posted 10 February 2011 - 11:44 AM

#21

Sweet pix!

I've only done one long trip... a 2-1/2 day trip from Salem, Oregon to Crater Lake and back... was 70% pavement, 30% dirt. Great trip, if cold.

Right now I'm planning a Death Valley trip (I'm in SoCal now). I did a daytrip to Joshua Tree a couple weekends ago but that was pretty boring. I need better dirt tires before I do much offroad stuff. My current rear is too worn to be useful in dirt.

Once the snow melts in the mountains, I'll probably head up there... but that'll be August probably.

Rob

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  • DRdeanman

Posted 10 February 2011 - 10:02 PM

#22

Well, not soon enough for me, but this summer I'll be doing a few rides. I think I'll ride down to Hood River in early June for the Black Dog Dual Sport ride. It's only a 2 day event but I hope to ride to and from, so that will make a 4 day trip.
Then, closer to home, I'll be riding the Hoh Rainforest with a small group. That's just a weekender trip but should be really good scenery.
I'm thinking about an adventure rally in Leavenworth in late June; the Touratech RawHide or whatever it's called. I'll ride there and back too, so that makes for a 5 or 6 day trip on the bike. Supposed to be good riding clinics and training/practice. I could use it!:ride:
And in August I'll be doing the Sasquatch, a 5 day ride through the twistys and dirt roads of Washington. :thumbsup: Last year's was great!
Plus I hope to do a week with the wifey on the Goldwing, and at least a couple weekend camping trips on the bikes.
I'm setup with Wolfman soft luggage for the 350, and some homemade panniers for the 650. They are a bit ungainly looking, but hold a ton, so I'll need to be careful not to fill them up! They are lockable and watertight, plus I don't worry if I scuff them or fall over on them. So far I have yet to test their crashworthyness.
54321, thanks for your post, you did a great job of selling me on the bike I already have:lol: Really a fine writeup of the DR650's ability to do whatever you need it to do, cheaply, reliably, quietly and fun-ly.

  • 54321

Posted 23 February 2011 - 10:35 PM

#23

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End of the season in the Sierra ... late October and just before it snowed on us.
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Near Mamoth mtn. ... and getting colder. Gerbing and Heated grips are good!
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Trinity Alps back roads in Summer
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Near Donner Lake
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Death Valley ... '07
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4 DR650's on this ride. Heading for lunch in Parkfield, Ca (Earthquake capital of California)

  • 54321

Posted 25 February 2011 - 05:46 PM

#24

I urge anyone riding a DR650 or prepping one for LD travel to check out the following Ride Reports over on ADV Rider. All are DR650 riders, most with great photos. Lots to be learned about what TO DO and what NOT TO DO, regards the care and feeding of your DR650. GREAT READING, take your time ... this is FUN!

http://www.advrider....ad.php?t=556240
Jammin' Jay ... still on the road. A great report.

http://www.advrider....ad.php?t=582578
Still on the road also. Adam switched over from a F650 Dakar BMW to a DR650. Stunning pics. He is now in Cent. America I believe and heading further South. Has been on the road for several years.

http://www.advrider....ad.php?t=600065
Now back in San Francisco after about a year. Great report!
Well written!

http://www.advrider....ad.php?t=549433
This is not a ride report but a great reference source to links for ALL THINGS DR650.
Excellent! :banana:

  • Buell78753

Posted 27 February 2011 - 06:33 AM

#25

Great thread with a lot of info! Nice bike pics too. I am always amazed by what a great workhorse the DR is! Those ADV links are very awesome base of knowledge on these bikes.

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  • 54321

Posted 02 March 2011 - 10:54 PM

#26

I rode the passes on the DR back in '08. Nice ride out and back too.
We did Ophir, Emogene and Cinnamon pass, some over 13,000 ft. The DR does not breath very well up there! 50/50 tires or knobbies recommended!
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Ophir pass area
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And this was in July!
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The DR650 did good compared to the KLR's on this ride. They all had knobbies... I was on street tire.
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Beautiful area!

  • 54321

Posted 02 March 2011 - 11:06 PM

#27

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  • Quercus

Posted 22 March 2011 - 10:11 PM

#28

Awesome thread. I've only done short trips, up to 4 days at a time, with the DR--but looking forward to many more, and much farther.

On the road to Bodie
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In Mendocino
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On the way to Stonyford
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  • 54321

Posted 15 May 2011 - 03:22 PM

#29

HID conversion for DR650
If you’ve ever ridden on a dark, Moonless night with no street lights and little traffic then you may already know the stock DR650 headlight ain’t much good. I recently up graded my ’07 1050 Triumph Tiger with an HID and was very impressed with the result.

For the DR650 I first ordered the 35 watt, H-4, Hi-Lo HID kit from DDM Tuning. This kit indeed has the H-4 bulb but is really set up for a CAR with two headlights. So, basically you get a whole length of harness you can’t use .... and the install is much more complex. The Triumph Tiger has two headlights but with the HID I use only one ... and that’s all I need. So I figured to do the same on the DR650. I sent back the Hi-Lo kit and got the $25 HID single bulb kit.

http://www.ddmtuning...egory.php?CA=61

They refunded my $15 (HI-Lo is $40). The new kit arrived in a couple days and was very straightforward to install on the DR650. You only have one beam ... but so far its a huge improvement over stock. HID bulbs have very long life ... but if one does go down, replacements are $15.

I’m not great at tutorials but here goes anyway:
Take off plastic headlight cowl.
This is what it looks like:
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Ignore my two brown wires ... they go to my funky headlight switch. Yes, if you ride off road this area may be dirty. Clean it up if you care.
Headlight has to come off to get to bulb. 4 bolts (two on each side)
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Headlight off, back of headlight. Carefully unplug three prong female from OEM bulb.
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Gently peel off rubber cover. Release spring clip and remove OEM bulb. SAVE for back up! (wrap in bubble wrap, put in plastic bag ... DO NOT TOUCH with bare fingers)
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Handle the HID carefully! Never touch it with bare fingers or skin ... or greasy rag. Remove from plastic holder it is sent in by twisting clear plastic tube counterclockwise. Thread HID bulb wires through stock Rubber boot dam and through HID kit rubber dam.
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You will have to pull through the HID kit power wires as they connect to OEM stock plug outside the headlight shell ... but there are options here.
Carefully install HID bulb into headlight shell. It only goes ONE WAY. Do Not Force. Once the three locating tabs are seated in the slots, lock in spring clip as normal. See above pic.

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Slip stock rubber boot along wires and replace back into its position over the shell.
Next, slide the rubber boot up the wires and firmly fit it over the bulb end. It should stay there.
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This is what it looks like now:
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At this point you have to start deciding where to stash the ballast and ignitor. I fitted mine up into the little shelf area in the headlight cowl. But there are options here and plenty of room for creativity. All the plugs on the cables have rubber, water proof gaskets and snap together nicely. THEY CAN ONLY GO ONE WAY ... so hard to screw this part up. Notice the two HOT WIRES (Hot and Ground). These go into the stock three prong headlight plug. You have options on where it can go. I plugged mine in and wrapped the plug up in the vinyl pouch with the rest of the wiring.

Notice only TWO of the three female plugs are used .... and they are NOT the same as the stock set up. The good news is plugging in any combo
will not damage unit .... but HID light will only work as shown below.
https://lh6.googleus...00/P1020199.JPG

Here is a before and after of the light against my garage wall. Very unscientific but there it is. This is Stock 55 watt Suzuki bulb.
https://lh5.googleus...00/P1020184.JPG
HID @ 5000K, 35 watt bulb. WOW!
https://lh3.googleus...00/P1020200.JPG
Stock Low beam straight on
https://lh6.googleus...00/P1020182.JPG
HID straight on. I guesstimate about 4 times brighter.
https://lh6.googleus...00/P1020201.JPG

I will update on this, but so far its an improvement. Dealing with the Ignitor/ballast require some careful placement. The pay off here is not only are you getting much brighter lights for cheap, but you're saving 20 watts (approx) over stock set up. On the DR, every watt is precious.
Hope this is a good starter for those thinking of upgrades. I'm sure I've left out a few things or made mistakes ... please chime in with ideas or improvements in the install!

  • 54321

Posted 20 May 2011 - 09:56 AM

#30

So I've had a few night rides in the last week or so. Wow! What a difference from the stock light. The HID is especially useful at high speed on our Deer infested roads. I'm seeing at least another 100 yds. ahead and picking up Eyeballs much earlier than previous.

I've also been running my 77 watt Gerbing at about 80% and Symtec heated grips on low (about 22 watts ?) Battery is holding close to full charge after two hour night ride. All good.

I have yet to do a really long night ride with heated gear. Previous 55 watt stock bulb, after about 4 hours Gerbing would begin cooling a bit as battery slowly went down. So the 20 watt saving with HID appears to help a bit here.
I hoping I can run my Gerbing at 100% at night for at least two to three hours and not run down battery too much.

For daytime, super cold riding I switch off headlight and run both Gerbing and
grips at 100% ... all good performance with headlight OFF.

The DR650 really only has about 60 to 70 watts free to spare for accessories.
Like always, a really healthy battery will always add a margin of safety on long tours where accessories are run ALL DAY and into the night.

Safe Riding! :worthy:

  • 54321

Posted 29 May 2011 - 09:17 AM

#31

Well ... that time again. Planning another trip South and time to re-check and service a few things before Fall departure. 2006 DR650, getting close to 40K miles. Haven't started this project quite yet ... but soon. Here are a few things I've got in mind to do before setting off on this 10,000 to 15,000 mile upcoming trip:

1. Rear wheel bearings
DR's seem to have a history of failed rear wheel bearings. Mine feel OK but at near 40K miles I'm changing them as preventive maintenance.

2. Front Wheel bearings ... fine but will do for PM.

3. Swingarm bearings
Never been checked. Time to check them out. This is a PITA and may need help from those more experienced here! :worthy::worthy:

4. Steering head bearings
These were checked and re-greased at around 15K miles. Time to check again. I've felt for notching and movement. All feels good and tight, steering is good. But I will go in and look CLOSE at the bearings ... will change them if they need it. Another PITA.

5. New Clutch Cable
Old one is fine ... but after nearly 7 years I think it makes sense.

6. New Twin-Air filter
Old one is a bit perforated, rotting. Pieces get into carb.

7. New Battery
Always good to do before long ride. Thinking of using the new Shor-rai Lithium-Ion one.

8. Re-Check NSU bolts
I did this a few years back ... will check again to make sure they
are still tight. (Used RED Loctite)

9. Clean IMS fuel petcock screens, clean IMS tank

10. Replace white plastic fuel inlet filter
Last replaced at about 20K miles and cleaned a few times since. It gets beat up removing and replacing. Time for a new one.

11. Check float level
This along with general check of Carb jets, diaphragm, needle, Jet needle,
Fuel-air mixture screw et al.

Most everything else on this old dog is still pretty good. No oil use, good power, motor a little more noisy than when new but starts and runs fine,
good MPG. Valves hold spec pretty well.

A few extras will be added:
GSXR pipe: I have the muffler but have not yet bought the Jesse mid pipe.
Tool tube
Fit tank panniers
New locking Fuel Cap for IMS tank

More to come .... :banana:

  • splurge

Posted 15 October 2011 - 01:08 AM

#32

That was very helpfull I have fitted a screen went for a 3 hour ride the noise and turbulence too my head near drove me mad,regret forking out the two hundred. I have taken 1oo mil off and will try again if no good will take the thing off. regards splurge

  • 54321

Posted 07 February 2012 - 05:48 PM

#33

DR650 Up Date

I did a short Baja ride in November. About 3 weeks on the road .. and took in a bit of the Pre Run action on the road. The DR was flawless as usual but on the way home I did feel some roughness in the drive line. This theme seems to come up often with DR650 riders. Even though I had a pretty good idea what the problem was ... your mind plays tricks on you in the middle of the Visciano desert.

But riders imagine all kinds of things; Is their clutch basket causing the rough feel? (It real feels like that) OR ... could it be a worn chain or sprockets ??
Or ... the Cush drive rubbers worn out?

So what was it? :lol:

My chain looked perfect ... only 10,000 miles on it ... I got nearly 24K miles on my last DID X-ring VM-2. The rear sprocket also looked pretty good too. Could it be the Cush drive? Nope.

As I always do ... I carry a couple front sprockets with me on longer rides. (gearing options) The front sprocket did not look that bad but swapping it out transformed the bike back to it's silky smooth self. Upon closer inspection I could see this sprocket was hooked a bit.

I put new front and rear sprockets on with the new DID VM-2 X ring chain 10,000 miles back ... and THAT is why I generally change out the DR front sprocket every 10K miles no matter what! Much smoother ride ... and longer chain life guaranteed. For a $15 sprocket ... this is cheap insurance! :bonk:

My Baja ride was only about 4000 miles total, with only about 400 miles of dirt and sand.

I am way behind on DR650 maintenance as I've been upgrading my other bikes and money/time is tight. My 1050 Tiger is up for a full service, total fork up grade and an a new $800 Wilbur's shock. I can do the service (most) but the suspension I must pay for. Not cheap! My WR250F has Carb troubles (a bog almost all of them seem to have) and is in need of a valve adjustment and a bunch of other routine maintenance I've put off. So the poor DR has been neglected to some extent.

I did manage one small job on my DR650 that I've been meaning to do for a while. The front end has been a bit harsh. The fork oil was old as well. So I took the forks off, dumped the old (dirty) 3 year/20K mile fork oil and cut the preload spacers by about a half inch. I also lowered the oil level about one inch. Result? A more plush ride in off road chop. More dive on the street under hard braking but a better ride over rough pavement. I like it!!

Next Up?
I need to replace my wheel bearings, Hubb bearings and all Cushion link bearings. There are 3 in the rear, two up front and the linkage as 3 or 4 more.
The wheel bearings feel OK but pushing up on 50,000 miles it's time for some preventative maintenance. My poor DR has earned some real TLC.

I'm trying to put together an Asia ride so no major rides planned for the DR in the Americas this year. I'll likely rent a 125cc in Cambodia or Vietnam and do some touring around. I've been 3 times to Thailand, twice to Cambodia and Vietnam. Fantastic people and amazing temples, rice paddies, mountains and Jungles.

  • smaas

Posted 07 February 2012 - 08:55 PM

#34

Great thread ! We did a ride last year and it was great. Made my own rear rack to hold a duffle, tent, sleeping mat, ect. (plastic cutting board, black in color so it matched). We are planning on longer rides this year so I am starting to prep the DR. Just got a set of pannier racks and I am now in surch of some saddle bags. I am thinking wolfman or Ortlieb panniers. My dream is to go on a multi week ride. I will get there one day. thanks for posting this and keeping it up-dated. It has answered some questions. I have been wondering around all these forums trying to gather up as much info on what to pack and what works the best. I think that has been alot of fun and has made my winter a little less boaring. Thanks again, its been a fun read !



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