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Old 06-14-2007, 04:42 PM   #1
LukasM OP
Beastly Adventurer
Joined: Nov 2006
Location: On a RTW ride - currently SE Asia on the way to OZ
Oddometer: 5,427
Lukas' Ultimate DR650 Adventure build up/ rebuild

So I am finally starting my next project. I would like to share this with you guys and hope to inspire some of the less mechanically inclined ones. It should help people working on their DR's as well as show you what NOT to do as I am sure to make plenty of mistakes.

The bike is a 96 DR650SE (except for a gasket the exact same thing Suzuki is still selling today) that I bought last winter real cheap. I plan on doing a trip from Vienna - Capetown down East Africa sometime this fall. I thought it would be a smart idea to really get to know the bike, replace all the wear items and improve some of the DRs weaker areas.

The plan includes the following upgrades:

Excel 21" front and 18" rear wheels for offroad
Excel 17" front and rear for supermoto
Front brakes:
Brembo 2 piston with 300mm rotor, 13mm (?) MC for offroad
Brembo 4 piston with 320mm, 16mm (?) MC for supermoto

WP 43 USD Forks with 20mm offset, custom valving and external preload-adjusters
Pro Taper Easton 28mm bars
Ufo hand guards with aluminum inserts
KTM EXC switches
Touratech IMO 100R300 with switches
Garmin 60CSX GPS with Touratech mount
IMS tank (and later Safari)
Wilbers rear shock
Hepco & Becker luggage rack
SW-Motech quick release side racks
Replace worn bearings, regrease
Metal base gasket
Holeshot Performance header
Aftermarket exhaust (probably LeoVince)
Dynojet kit

Also, since I have a scale in the garage and somewhat of an obsession with weight (being a wannabe racer), I will keep a running tab of the part weights as I add them to the bike. Maybe they will help someone who is trying to get the weight down to something more off-road worthy:

Frame (helmet lock yet to be taken off): 16 kg
Wilbers Shock: 3,4 kg
WP 43 Forks with triple and handlebar mount: 12,5 kg
Stock engine with oil and oil cooler: ~50kgs!
21" complete Excel front wheel with tire (90% thread): 9,1 kg
IMS Tank, plastic cap, petcock: 2,9 kg (I read somewhere that stock is 4,5 kg)
Left side case saver: 0,1 kg
Ufo hand guards: 0,6 kg
Wiring harness: 1,1 kg
Stock Pegs: 1,1 kg
Sidestand: 0,6 kg
Throttle tube with cables: 0,4 kg
Front MC: 0,4 kg

Plastic undertail: 0,7 kg
Rear handles: 0,75 kg
Sidestand safety switch: 0,1 kg
Currently going RTW on a KTM 690 Rally, trip blog:


LukasM screwed with this post 06-16-2007 at 07:04 PM Reason: Updating
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