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Old 04-07-2014, 04:47 PM   #1
Trayvessio OP
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DR200SE-ADV Build Thread.

Transforming the DR200SE into the DR200ADV.



My girlfriend wants to ride motorcycles. I love motorcycles, especially ADV bikes. So I set out searching for an inexpensive, reliable, lightweight, low-seat height, and fun motorcycle for her to ride. Originally I was searching craigslist for XT225's, Super Sherpas, and KLR250s. Eventually, my searching led me to the DR200SE. Relatively light weight (278 lbs.), reliable as a claw hammer, low-seat height, and HUGE GAS TANK (3.4 gallons for a 200cc single? Yes please!).

… And then I started reading reviews…

"It's too slow," "the suspension is crap," followed by "it's really slow," and "the suspension sucks." These seemed to make up the majority of the criticism against the little DR.

The slow - we can deal with that.
The suspension - might need to fix. We shall see.

I happened upon a very lightly used 2013 DR200SE at my local Guzzi dealership at an attractive price. I called and put it on hold and then later that week went down to give it a spin, then bought it. I don't care what anyone thinks, the little DR200SE is fun! I love ripping around on this thing. We are still waiting for my lady to get her endorsement, and I think she is worried that I won't hand it over when the time comes.

More to come.
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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 04:52 PM   #2
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Drastic Weight Loss

I think the DR200SE is pretty light at 278 lbs. However, it's come to my attention that some of you think that qualifies as "heavy." Out of concern for what you FF's think about my motorcycle, my first modification is to take some pretty drastic measures to reduce the weight of the DR200ADV.



Dieting done - time for carb loading!
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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 05:03 PM   #3
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Rack #1

Once I installed panniers on a motorcycle and freed myself of the oppression of carrying things around in a backpack or a messenger bag, I swore an oath that I would spend the rest of my life freeing others of that same burden. Stock, the DR200SE does not offer cavernous storage capacity. Actually, in stock form, the DR200SE offers approximately zero storage capacity. This is unacceptable for the DR200ADV.

First step was a front rack. In the bicycle world, front racks are really cool these days (people like to think they are randoneurs which means "dork" in French). Because I am a mindless Fashion Zombie, I decided I would install a front rack as well.

Manracks came through with a front rack. Mike shipped my rack pronto and it arrived the same. Thanks! I was very happy with the quality of the rack, and the weight was minimal (maybe 2.5 lbs?).

Checking the fit.


I was very happy with the quality of the rack, however, the fit was not perfect. I had to bend one of the tabs on the rack to make it fit flush.



Slight fitment issue here, but me and Mr. Vice got it solved.

The rack looks awesome! Overall, very pleased!

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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 05:11 PM   #4
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Superbug!

I want to stop here and give a shout-out to Ladybug0048 and Superbug. Reading her ride reports has entertained and inspired me through many hours of class. Living on the wet side of Washington state, maybe some day our DR200's will cross paths.

As far as I'm concerned, Superbug is the original DR200ADV. Respect.

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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 05:32 PM   #5
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If one is searching for a rack to carry panniers on a DR200SE, one will very quickly discover Happy-Trails. I've had a Happy-Trails SU rack and pannier setup on my DL650 for 45k miles with zero complaints.

However, I purchased my DL650's setup in 2010 and the entire setup cost $677. Today, in 2014, a pannier setup for my DR200SE is close to $1000. Now, I think they make a quality product, but it's harder to justify the cost considering how much I spent on the bike itself.

So, after much deliberation, I elected to purchase a Happy-Trails SU rack and pannier mounting kit. Then I turned my attention to boxes. I was worried about fitting this mini-ADV bike with maxi-ADV bike panniers, which would be silly. So after perusing many threads, I decided on Pelican 1500 cases. A quick search on Amazon turned up some closeout bright orange 1500's for $76 each. Done and done.

Tipping the scales at 7.2 pounds.


Boxes of stuff to install! Please ignore the uninstalled Manracks front rack - there appears to be some problem with the space time continuum here.

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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.

Trayvessio screwed with this post 04-07-2014 at 07:15 PM
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Old 04-07-2014, 05:33 PM   #6
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Build Thread Misnomer

I think it's funny, the idea that this is a build thread.

"Build thread?" Really? I'm not building a bike here. A bunch of people in another country "built" this bike.

Being generous, one might call this a "modification thread."

Or maybe, an "accessorizing thread."

Most accurately, this is a "bolt stuff onto a bike thread."

But I digress.
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Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 05:42 PM   #7
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Happy-Trails Rack Install

So, I began installing the Happy-Trails SU rack. The first step in the directions is "uninstall the turn signals." Okay - how do I do this? I tried to unbolt them but it's not as simple as that.

Enter my father, who was an electrician in a past life, who saved this project from my unskilled hands today and is the reason why the turn signals on the DR200ADV work today.

We marked and cut the turn signals and removed them. Re-installation info later.

I started fitting the rack to the bike. First bolt went in fine, passenger peg bolt went in mostly fine, everything was going pretty well, until I went to fit the third bolt and encountered…. this:



Hmmm… this doesn't seem quite right. Shouldn't the holes line up so that the bolt can go through?

After various attempts to bend the rack to fit, we eventually decided to drill out the turn signal mount hole to make the rack fit. The first time we drilled, the bit wandered and drilled a little bit further up than we intended, however, this turned out to be the right placement, and the second hole got drilled out accurately and easily.

Rack installed! The empty brackets are for the turn signals.


(I just noticed the hammer sitting on the seat. Yeah, that's how we roll.)
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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 05:47 PM   #8
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Next step was fitting the cases. I was thinking about just drilling some holes and seeing how they fit. My father, a rational man, had a better idea: make a template.



The new Happy Trails Point1 racks fit differently than my old SU rack on my DL. The new racks use threaded inserts on the top and pucks on the bottom. So it's pretty important that the holes line up.



After insuring the template was correct, we transferred the template marks to the case and bolted it up. Moment of truth….



Looks good!
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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 05:48 PM   #9
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That's all for now! We got the turn signals re-wired and I got on the road in time to make it to school. I will take some pictures of the completed cases soon!

There is still more to come. Skid plate on order, foot pegs on order, and handlebars and brush guards on the horizon.
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Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-07-2014, 06:18 PM   #10
WYO George
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This'll be a fun one to watch. My wife had a DR200 once and I have a great respect for the "little DR".
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Old 04-07-2014, 08:23 PM   #11
AJay112
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Old 04-08-2014, 01:24 PM   #12
Trayvessio OP
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I'm thinking I might keep this bike for myself. Or get my own, paint it black, put an FMF pipe on it, and annoy my neighbors.

So much fun riding around. It's also sunny here for the first time in a while. Nice!

Hanging out.


Rad bike!


Here it is parked with my big bike (and by big I mean 650 twin oh yeah).
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Currently: 2008 DL650, 2013 DR200SE-ADV.
Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-08-2014, 03:23 PM   #13
MrPulldown
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Nice thread. Always liked the 200. I guess others did too and thus it still lives on whereas its big brother the 350 was killed off.

BTW the 200 and the 350 share some of the same parts. For starters the headlight cowl are exactly the same.
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Old 04-08-2014, 03:32 PM   #14
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Quote:
Originally Posted by MrPulldown View Post
Nice thread. Always liked the 200. I guess others did too and thus it still lives on whereas its big brother the 350 was killed off.

BTW the 200 and the 350 share some of the same parts. For starters the headlight cowl are exactly the same.
If I could buy a brand new DR350 for myself, I'm pretty sure I would. Small displacement? Check. Six-speed? Check. Reliability? Check. Oh well. The 200 is still fun.

But man, six-speed….
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Gone: 2000 Aprilia Pegaso, 1983 Yamaha XT200, 2008 Kawasaki KLX250-SF. 2005 DL1000 DMC/Ural.
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Old 04-08-2014, 11:13 PM   #15
Te Hopo
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What a great looking bike, I'm sure it's gonna give you plenty of rewarding service.

A his and hers in black and white would look really good and make for some great adventures
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