Bikes: 2012 Suzuki DR650

July 2022

The unfortunate theft of my previous 500 gave pause to consider my bike strategy. I really didn't have the appetite to build another KTM, nor did i relish the thought of rattling about atop another.    Thankfully, the fortunate arrival of the insurance money released some creative energy and a US import was acquired.  

 

The venerable DR650, air cooled, dual sport dinosaur of choice for round the world travellers.   This particular model had one owner and sat in his living room for 11 years.  Pristine. 2000 miles and rare as hens teeth in europe.

I'm going to change as little as possible, experience teaches that much of what you add is less reliable than the OEM spec.

Update August 2024 

I've completed almost 10,000 miles on the DR now and it's proved itself to be very hardy and reliable.  It absorbed abuse from the Sahara desert, Dakar Beech, Welsh Rallies, EU TET trips, Alps mountains and 1800 miles from Romania to England.  

I find it exciting to ride both on and off the road and light enough to pick up alone. I'm able to maintain it with basic tools and I trust it to get me home on the road. My unicorn go anywhere, do anything, Adventure Bike.

The modifications I list below are holding up well, where anything fails or falters, I update the notes. The seat is wonderful, all day, multiple day, comfortable

Fuel Range

20L Acerbis tank fitted.  They also do a 25l variant, but it sits much large on the bike and i didnt fancy the extra bulk.   Completed a 195mile test and used 15.5litres of fuel. 12.5mpl x 20L = 250miles 

Wheels

Excel Black Rims and heavy duty stainless spokes. 

Suspension

The Stock suspension is under sprung and mushy and not made for my weight. Rear was replaced by a Cogent Mojave shock with Ohlins spring.  The front springs were uprated for my travelling weight and Cogent DDCs. 

Seat

Seat Concepts Comfort High.  (I'm tall)

Bars

Replaced with Renthal High Bars, for strength and comfort. Grips were replaced with anti vibration rubbers.

Protection

Acerbis belly pan, frame and tank protection and hand guards. Extended the rear shock mudguard to further protect the shock.

Rear Rack

Low profile option from Procycle.

Items that failed

Swapped the mud guard, then put it back to stock, (the alternative item covered my coat in mud)

Swapped the indicators, then put them back to stock. (the alternative items failed after one trip)

       

Weight Reduction

Pegs - Lowered and lighter models installed

Rear Bars - removed.

Bar end weights - removed.

Exhaust - Replaced with a titanium Suzuki GSXR OEM (e) marked.

Rear Fender - replaced

Rear Light - replaced with smaller model

Helmet lock - removed

Battery - replaced with lithium.

If Chuck Norris made bikes....   Ready for Africa first and who knows where next.

Service History

2022 - September - 2500 miles 

Oil and Filter. Carb Filter - replaced

Exhaust - removed, cleaned and welds shaved down. 

Stainless steel braided lines replacing the old rubber.

Lithium Battery Fitted.

NSU - checked tightened

Countershaft seal retainer added.

Carb cleaned, checked, recalibrated and all rubbers replaced. (no mods)

Airbox - cleaned and Motrex filter added (the last was falling to bits after 11years)

Front brake pad replaced. 

Tyres: MT21 front. Mitas E09 rear fitted

2023 - February - 5535 miles 

Oil and Filter, Air Filter, Valve clearance checked and exhaust port adjusted.  LED Bulb.

Starter motor - removed and bearings greased

Tyres: part worn Shinko 244 Rear fitted.

2024 - March - 6683 miles 

Tyres: rear Mitas E07 fitted 

2024 - April - 7828 miles 

Oil and Filter, Carb Filter, Air Filter.

 Front and Rear wheel bearings.  

Rear brake pad replaced. 

Rear caliper service(cleaned, inspected and greased)

Stand switch removed - it kept stopping the engine in water. 

Stand switch relay diode - replaced. 

Clutch switch - removed. 

Front headlight reflector - swapped with a Z-Offroad LED sealed unit.   

(OEM was turning yellow and was stained with something)

Tyres: front - Part worn Tractionator Desert H/T fitted. (Had a trip to the Alps and needed just a 1000miles) 

2024 - May - 8902 miles 

JT 15 tooth front sprocket installed.  (Chain and rear look OK)

Front right fork was leaking. Replaced both sides with new seals. 

Part worn TKC80 front tyre fitted.

2024 - July - 11079 miles (after Romania+ Europe trip)

Oil & Filer

Chain & Sprockets replaced. 

Rear brake caliper binding, cleaned caliper and replaced piston seals.

++++++Part Specs++++++

Plugs CR10E

Engine Oil.   10w - 40.   Semi Synth

Engine Oil volume: 2.3l 

Engine Oil change: 4000 miles (Forums say 1500 - 3000m)

Engine Oil Filter: HFF3025 (easy to get UK)

Oil Filter Interval: Every other oil change.  (Forums say filter every time)

Fork Oil         5w     With cogent DDCs fitted (10w standard);

Fork Oil Amount:   600ml with 130mm gap from compressed fork top. (Forks empty)

Tyres Front  90/90 21

Tyres Rear.  120/90 17.  130/80 17 also fits

Chain.             525 x 110

Sprocket        15T/ 42T

Front Wheel 

Bearing.        17mm x 35mm x 10mm, 6003 Part: SKF 6003 2RSR (x2)

Seal.                23mm x 35mm x 6mm Part: 09284-23001 (x1)   

Suzuki drz250 dr350 rmx250 XF650 - all the same. 

Rear Wheel

Bearing           20mm x 47mm x 14mm, 6204 Part: SKF 6204 2RSR  (x2)

Seal.                 26mm x 47mm x 5mm Part: 09283 26019 (x1)

Cush Bearing. 25mm x 52mm x 15mm, 6205 Part: SKF 6205 2RSR (x1)

Cush Seal.        34mm x 52mm x 6mm Part: 09283-34003 (x1)

Seals - single lip end shaft seals available 3rd party.

https://showe-performance.co.uk/34mm-x-52mm-x-6mm-tc-oil-seal.html

Fork Seals        56-136 'All Balls' kit.