DR650 Modifications List

May 14, 2019 — Various

Here is a list of modifications made on the bike and a few comments on them.

When I refer to the TAT, it means the Trans-America Trail. This trail is quite difficult and taxing for the equipment. This part of the trip was done with two partners.

rear shock

−	new valve and 0.76 kg/mm spring
−	too soft, replaced in Ecuador for a stiffer one (specs ?)

fork

−	0.45 kg/mm spring (I think)
−	rebound is still too high (re-valving?)

fuel tank

−	Acerbis 25 litres / 6.6 gallons
−	two petcocks
−	each petcock has its own fuel filter (Procycle)
−	locking cap
−	indicator relocation bracket (Procycle)

standard SeatConcepts seat

−	much better than OEM

	countershaft sprocket seal
	magnetic oil drain
	skid plate

−	already there when the bike was purchased, unknown brand

	headlight guard (Procycle)
	Neutral Sensing Unit (NSU)

−	Procycle kit

	extended fuel screw (Procycle)
	secondary air filter from Procycle
	licence plate

−	added a bottom screw

upper drive chain roller

−	removed and replaced by screw

lower drive chain roller

−	replaced by a better quality part

rim lock

−	only one on the rear wheel - installed at 180°
−	removed in Mexico, too difficult to install when having a puncture

Renthal Standard 7/8" handlebar - CR High

−	Bikemaster riser (about 4 cm)

handguards

−	Barkbusters Storm Handguards

OEM pegs

−	too high for me, very bad
−	trashed after the TAT
−	replaced with Procycle pegs (they are lower)

Procycle pegs

−	much better than the ones from Suzuki could be even lower

	SW-Motech centerstand
	new mirrors

−	KTM Military - 280 mm

tool box

−	replaced OEM box with Procycle one

	bypass side stand switch
	kept clutch switch

	Happy Trail Teton 9" luggage system;

−	with tail plate
−	aluminum panniers without any coating)
−	rack and tail plate seem very solid
−	pannier quality is very good
−	after the TAT, I think that the mounting bracket is weak; a system with bigger washers/plastic mounts would be better
−	pannier racks often break on minor falls... strengthening them is risky since a pannier or the frame could break instead


	voltmeter

−	needed with heated grips, heated vest, headlight, and electronic gear recharge
−	Procycle voltmeter broke after a few months, I now use a voltmeter connected to a SAE connector

GPS

−	Garmin 276cx with AMPS mount

Inreach - satellite communication system

−	with adequate mount


	heated grips

−	Bikemaster - 36 Watt
−	works very well

SAE connectors for charging electronic equipment

−	3x front (various fuse), 2x rear
−	via a 30 AMP standard automobile relay

connector for the heated vest - proprietary

−	via a 30 AMP standard automobile relay

headlight switch

−	needed so that heated grips and vest can function at the same time

heated vest

−	Venture Heat
−	piece of crap used only 3 times, the wires inside broke

Popular modifications I choose not to do:

	no wind screen
	lighter exhaust pipe
	no carburetor re-jetting
	no engine guard
	no automatic chain oiler

Spare parts:

	clutch lever (2x)
	front brake lever
	rear brake lever
	gear shifter lever
	bulbs 1xH4, 1 flasher, 1 brake
	regulator
	pick-up coil (aka pulse coil)
	standard front/rear tube
	clutch cable
	throttle cable
	12V relay
	fuel pipe
	oil filters
	Emergency Oil Cooler Bypass (Procycle)
	remote choke (can be installed directly on carburetor)

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