Travels around the world 2009-2024
Exploring our beautiful planet

DR650 Modifications List

May 14, 2019  —  Various
Quebec City - Quebec - Canada

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)