DR650 Modifications List

The following is a basic list of the modifications we made to our Suzuki DR650SE motorcycles to convert them into travel bikes ready for the road.

Ergonomics

  • Rox Risers Elite 2″ pivoting handlebar risers
  • Highway Dirt Bikes (HDB) ADV handlebar top clamp
  • ProTaper Contour Handle Bars:  ATV Mid (AT), RM Mid (JP)
  • Motion Pro Throttle Tube
  • ProGrip 714 Rally Grips
  • Sargent Seat, regular height (AT), lowered model (JP)
  • IMS Super Sport Foot Pegs (JP)
  • Pivot Pegz Mk3 (Yamaha YZ) and ProCycle lowered foot peg brackets (AT)
  • SW-Motech centerstand
  • Beaded seats, customized from automotive style, painted black
  • Laminar Lip B-King Windshield (AT would prefer more coverage)
  • Rearview mirror, blind spot, automotive
  • Highway pegs, Happy Trails, Universal
  • Kaoko throttle control (KLR +08 /w hand guards model – KBB300)

Engine and Drive

  • Neutral Sending Unit (NSU) fixed
  • Upper chain roller removed
  • Extended fuel screw
  • Chain rollers: upper removed, lower replaced
  • Partial full snorkel-rectemy
  • Nova Racing third gear set installed
  • Bike Master magnetic oil plug installed — to collect engine bits
  • K&P Stainless steel oil filter
  • Stainless Allen Steel Carburetor Screws installed
  • 32 litre Safari tank, neutral colour
  • Cogent Dynamics rebuilt stock shock with Eibach 8.4 kg/mm spring (AT)
  • Cogent Dynamics rebuilt stock shock (lowered) with Eibach 8.1 kg/mm spring (JP)
  • Eibach 0.50 fork spring  (AT)
  • Eibach 0.48 fork spring (JP)
  • Ricor Racing Intiminators
  • New OEM front and rear sprockets
  • New DID 525 VX chain
  • New Galfer green front, and black rear, brake pads – problems with Galfer greens on DR and KLR (no more)
  • New All Balls front and rear wheel bearings
  • New cush rubber (JP), AT shimmed with inner tube
  • Loobman gravity fed chain oiler

Electrical

  • Disabled clutch “safety” switch
  • Disabled side stand “safety” switch
  • DEKA ETX9 AGM sealed battery (JP replaced with other in Colombia)
  • High Output 250 Watt Stator
  • PIAA Sports Horn
  • Backoff XP brake light modulator (excellent)
  • Symtec grip heaters (would consider Warm N Safe modulator, rocker switch not weatherproof).
  • Trail-Tech Vapor Speedometer/Tachometer
  • Fenix Cree900 High Intensity LED Lights, mounted on hand guards with DIY mounts
  • Aux light relay installed, stand alone (left console), or linked with Hi-beam (HDB dash)
  • Passing light circuit enables, momentary switch on left console
  • Eastern Beaver H4 headlight kit with LO beam cut adapter (on HDB dash)
  • Eastern Beaver PC-8 and 30A Relay Kit
  • Powerlet socket on HDB dash and rear subframe
  • Electrical Connection LED Motorcycle Battery Voltage Monitor (HDB dash)
  • Warm N Safe wireless Heat-Troller mounted on brake reservoir

Protection

  • AMP engine armour
  • Rear master cylinder guard
  • SW-Motech skid plate
  • Highway Dirt Bikes (HDB) hand guard system (touring size) with spacer on left side

Luggage

  • Happy Trails SU Rack
  • Pelican 1550 case system with lid stays
  • Givi case lines – simple suitcase that fit the Pelican cases (OK but not perfect)
  • Pro Moto Billet (PMB) tail rack (slightly bigger rack might be better)
  • Ortleib Moto Rack-Pack dry duffel (89L)
  • Sherpak Cinch straps (MEC)
  • Wolfman Explorer Lite Tank bag
  • Twisted Throttle “tractor manual” Tool tube
  • 4 Litre Roto-Pax water carrier with mount (next time 2L pop/soda bottles – too heavy, fragile (fell off))
  • US military issue auxiliary pouch for extra storage (gifted to us by Erik M.)
  • The ammo dump bags fastened to our tanks and case for extra storage
  • Homemade ABS tooltube affixed to our skidplate for storing tools and spare parts