Hi,
I'm setting up a 650 for Aussie late next year and South America after that. I've been all through this website, taken the bike for several small trips, used my engineering and back country experience and come up with the following concept to create what I rekon will be the ultimate long-distance, unsupported 40/60 on/offroad cycle:



more info : http://www.yonder.orcon.net.nz/moddedXR

But I know I won't have got it completely right, or maybe not right at all. Any comments? Things I need to add or remove?

Cheers,
Matt

[This message has been edited by mattmbishop (edited 14 December 2004).]

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TDM850
www.aussie2006.webset.co.nz
www.europe2007.webset.co.nz

Yep, when you park your bike to go sightseeing is everything secure? Like is someone going to be able to pick up your saddle bags and walk off with them.

cheers
alec

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Close to Antarctica and a long way from reality

I have the same bike and like to off-road so I did a few more mods on mine. I'd reccommend metal guards where stock is plastic, almost all of the ones I changed were damaged already from normal wear and tear . I'd also reinforce the rear subframe if you'r packing any weight on the rear end. Check out my scooter here
http://www.telusplanet.net/public/pjplan/history

don't stiffen the front springs, but drop the yokes down the stanchions by 20mm to improve the handling with all that weight so far back.
also, get a stiffer rear spring. 20% is about right.

the bike can handle a lot of weight over either wheel, but go low and forward compared with your sketch. you'll be working the rear tyre hard

Thanks for your replies fellas and sorry if that drawing disappears from time to time, I'm having isssues with my ISP,

Simmo, I understand that the saddlebags aren't really secure, but they're my concession to historical and aesthetic values. Basically, my Grandad was into leather in a big way, he even made his own saddles, so I thought if I was going tripping I would make some leather saddlebags of my own. 'sides, one of those pack safe thingies over the back should be secure enough and I'll lock the saddlebags themselves to the bike.

Scooter, good call on the metal guards. On inspection, it seems my plastic guards are pretty bashed as well, 'specially the back disk brake cover. I'll definately be reinforcing the sub-frame. I'm even intending to FEA the frame to see what sort of stresses are there. A bit OTT, but I use the software all the time at work so it's no big deal.

RichLees, I'm intending to get the suspension sussed once I've got all the weight on. 20% stiffer on the rear, I'll keep that in mind. By yokes you're refering to triple clamps, right?

[This message has been edited by mattmbishop (edited 19 December 2004).]

__________________
TDM850
www.aussie2006.webset.co.nz
www.europe2007.webset.co.nz

triple clamps ... I think they're quadruple for what its worth, but, yes, the clamps around the gaiter-covered, chrome-plated stanchions. makes a significant difference to handling on the road, too
have a good trip

For what its worth you'll find my 2ç's worth on prep here:
http://www.adventure-motorcycling.co...rs/xrlprep.htm

There's a dvd of XRL action there too somewhere.
I believe Desert Rider Escombe may be selling his Shed Rouge.

Chris S

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Morocco Overland 4 (2025) • Trans Morocco Trail

I agree with most of the stuff already (nods to the experience of CS and RL). I would seriously consider ally cases if I were you. I had stuff *unbolted* from my bike when I wasn't standing next to it, so anything strapped on with webbing / leather should be considered disposable. In terms of the bike:

Heavy rear spring essential, Front Eibach springs worked for me, and I dropped the yokes too. Makes a massive difference especially with a full tank in sand. Better to leave the stock tank and get the jetting / exhaust sussed for good economy, and carry a jerry for emergencies / long legs. Sheepskin essential for this bike (or air saddle doohicky / gel saddle mod). I took a tin topbox - not sure I would again, but it saved me having any horrible tankbag monstrosity. Again, armour the bike as if it is going into war. The sumpguard, frameguards and headlight protector on mine saw enough action for em to be convinced they stopped me having some serious hassle.

Great bike. Fast enough if you think carefully about balancing it, and chassis / exhaust mods. Michelin Deserts and *proper* rim locks. 4mm Bridgestone tubes. Daily mechanical checklist. Check oil carefully, often. Don't let it get too hot (or you could drop a valve seat). Don't ride along in too high a gear - nothing wrong with revving it a bit. Change the bars for comfortable, rigid ones (renthal / fatbars?) Wider footpegs are worth 5mins with a welder. Gussets on the subframe are worthwhile.

Lots more at www.pm-04.com (I'm a terrible bike geek). The photo pages are all messed up, but all the pics are also available through www.pm-04.com/galery



Hope this helps.
Just sold mine. Very traumatic indeed.

------------------
=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!



[This message has been edited by POB/London (edited 30 December 2004).]

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=-=-= ON THE EDGE! =-=-=
My XR650L Pan-Med Expedition Site!

hey check this site

http://www.xlv.ch/index.html

Looks a good reinforcement idea.
KH

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http://vientoderipio.blogspot.com/
America is a nice continent,not a country.All people who lives in this continent are americans.Discover it in peace!

Thought I might post what I ended up with, a year and a half after my original post and one month before leaving for Aussie.

Basically, I disregarded any alloy box design and went with saddlebags. I'm still aware of the security issues, but removable saddlebag inners and a pac-safe goes a long way to getting around that.

Major mods:
- 20 l acerbis tank
- front and rear luggage racks
- re-foamed and upholstered seat
- leather saddlebags
- 6 litre under-engine water tank
- highway pegs
- barkbusters and highbars
- cigarette lighter

If anyone is interested, there is more information on our website: www.yonder.orcon.net.nz/aussie2006.htm. Thanks for your help over the past year or two guys.

Attached picture is the bike as shipped to Aussie yesterday.

Attached Thumbnails

 

__________________
TDM850
www.aussie2006.webset.co.nz
www.europe2007.webset.co.nz

have a great trip! who fabricated the bash-plate/tank? what did it cost you?

We've taken to calling it a bashtank.

My friend Doug and I built three of them. We're Mechanical Engineers during the day so it wasn't hard to design the tanks, it was a bit harder to learn how to weld aluminium though. We made three of them and after spending a whole day getting the first one watertight, we got the other two welded by a professional.

I couldn't tell you how much it cost, as we did most of the work ourselves. There was probably 2 full days of design and 2 days to weld and fit the tank. At $50 an hour, that's probably $200 of labour. Materials cost was about $180 per tank so I'd estimate the cost at around $400 NZ.

The tank is full aluminium construction, 3 mm plate, but still weighs about 4 kg. However, we figure this is a decent tradeoff to be able to carry 6.5 l of water right below the engine.

I've attached another photo of the tank. Unfortunately it's a bit blurry.

Attached Images

 

__________________
TDM850
www.aussie2006.webset.co.nz
www.europe2007.webset.co.nz

Great work man!
Hope you keep us updated with the bike performance.As i know Australia(outback)is very rough!
Take care
KH

__________________
http://vientoderipio.blogspot.com/
America is a nice continent,not a country.All people who lives in this continent are americans.Discover it in peace!