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The DDPP (Definitive DR Prep Project) The DDPP (Definitive DR Prep Project)
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Photo by Marc Gibaud,
Clouds on Tres Cerros and
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Old 12 Oct 2007
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Join Date: Oct 2007
Location: London
Posts: 301
The DDPP (Definitive DR Prep Project)
PREPS FOR LONG HAUL
– This is just collation of members' posts collected into one place, in an ordered way - to make things easier to find
– Specific to DR650, but most things generic for all bikes
| NOTE: || Its a work in progress - || if you've got something to add, or I've made an error, || please comment. I will update as and when. |
INDEX:






1. Lose Weight

2. Get fit and stay beautiful (Endurance & Reliability)

3. Dont forget the feather pillows (Mods for comfort)

4. Louise Vuitton or Chanel? (Luggage options) [tbc]

5. Whats in the handbag! (Tools & Spare Parts lists)

*********Loose Weight!********
Mods to save weight

• Remove passenger pegs

• Replace rear license plate light and assembly, install a LED license plate light

• Remove Helmet lock (ground clean off frame)

• Replace some bolts with Aluminium in unstressed locations –
–may not be a good idea for serious ofroading, due to differing metal strenghts

• Replace odometer
–Digital Panoram / Sigma BC800 bicycle computer


• Replace factory pipe with good aftermarket pipe

• Remove 1/2-3/4" from side stand

• Swap stock indicators for smaller, lighter ones

• Replace stock seat with Corbin (comfort and weight saving)


**Get fit & stay beautiful**
Improve endurance and reliability


• Upgrade chain rollers [Lone Rider] Bolt spares on to the right side where the pillion peg mounts [ ]

• Upgrade your warranty – available for second owners, up to 5 years [Lone Rider]

• Add an inline fuel filter
cheap, available at all major auto pats stores.made for lawn mowers.doesn't require clamps. The 1/4" line can be pushed over 5/16" inlets/outlets. [Lone Rider]

• Replace factory pipe [Molly Dog]

• A few 1" holes in the top of the air box should also help it breathe better[Lone Rider]

• Replace chain
–with DID 525 VM X-ring. Lasts double longer. [Mollydog] [LeCap]

• Wrap header pipe
–Engine runs cooler, better mileage. [Lone Rider]


• Replace Tyres
–MEFO tires went the entire way with some serious dirt and rock sections; I recommend them. They don't hook up quite as well as TKC80's. smoother ride on pavement and last much, much longer.[mrdnd]

• Home made stand offs for bags[Molly Dog]

• Replace or modify Indicators
– bolt front ones under the handle bars, using the mirror mounting, behind the bark busters. less likely to get hit! [Frank Warner]

– I made them flexible using rubber fuel hose. [Molly Dog]

• Replace suspension
– The Eibach F&R make an amazing difference [Fat Chance]

• Replace screws with stainless steel cap screws
– Esp on the carb, switch blocks, coil, and body. Stock fasteners have a reputation for being very soft. [bartman 10]

• Add a homemade headlight guard bent up from a piece of Lexan [bartman 10]

• Add Scottoilers
– kept our chains very clean. mounted on the main frame near the carb, cutting into the vaccum line for the fuel tap. [bartman 10]

• Strengthen main wiring loom - put some spiral wrap around where it chafes on head stock.[Bartman 10]

• Replace sprockets with JT Sprockets[Molly Dog]

• Sealed spoke nipples on front to slow air loss[Molly Dog]

• New brake pads f&r (EBC sintered)[Molly Dog]

• Brake systems flushed. all new fluid[Molly Dog]

• Fit braided steel brake lines [Nigel Marx]

• Fit rim lock to stop tyres slipping in mud [Geordie]

• Air filter socks. Slips over standard filter. Replace when dirty. Reduces frequency of filter replacement. [Frank]

• Engrave the inside of the valve covers with the clearence values. [Frank]

• Lower chain guide
- make out of multiple bits of chopping board. Rotate when worn - extends life. swap with outer bits so have built in 'spares' [Frank]

• Replace headlight bulbs for brighter - more here http://www.horizonsunlimited.com/hub...741#post146788

**Louis Vuitton or Chanel?**






The luggage debate
– I'm still working on this section, since there is so many options and opinions all over. Perhaps just leave it for the 'Equipment Forum', HOWEVER, Peli Cases seems to be the fashion accessory of choice on the DR forum [Molly Dog, Fat Chance, Lone Rider, mrdnd, Mountainman]






**Dont forget the feather pillows**
Improve comfort on the long haul

• Wind shield
A tall Parabellum wind shield -- dangerous for dirt work. Using wingnuts and thumb screws, I can remove it within a couple of minutes and store it under a net on the rear. [Lone Rider]

• New foam grips on the bars – reduces vibration [Lone Rider]

• 12 volt switched plugs
– One up in the headlight, another above the shock and a third on the right near the CDI box. [Molly Dog]

– Wired (w/fuse) a cheap marine 12v outlet to the battery and mounted it under the BBQ [Lone Rider]

• Replace footpegs
– With WIDE IMS Pro series, Really reduces fatigue while standing for hours dirt riding.

• Installed ProTapers, using custom made gromets to allow the use of my stock bar ends

• Heated Grips
– Heated Symtec grips. zipped tied to Idiot light module. bought a rubber sleeve for the toggle - made a a rubber "dam" out of inner tube to go over the switch itself. [Mollydog]

– AeroStich wrap-on heated grip thingies. They take a couple of minutes to put on...and really work. No problems losing heat thru bars and grips. But they are another thing to store when not being used....[Lone Rider]

• Louder horn [Molly Dog]

• Hand Guards
– $30 TUSK items are not only the best quality of ANY Alu handguards I've seen, but also have the most clever mount system that offers the best adjustability of any I've mounted. [Molly Dog]

– Throttle lock [mrdns]

– Sheepskin for the stock seat. Done several 500 km days on the DR without complaint [Bartman]

**Whats in the handbag?**
Spare Parts & Tool lists

– Working on this section..
__________________

Some great quote about hard core travel that nobody has said yet.[/URL]
Last edited by XT GIRL; 17 Oct 2007 at 05:37. Reason: removed (for now) non DR items.. added stuff
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