Not a difficult job but requires some finessing and bending in a vise, especially for the mount above the exhaust, at least the way I did it. You can see the brace in this pic.

http://i8.photobucket.com/albums/a27..._Annotated.jpg\

Here's the other side for the heck of it.

http://i8.photobucket.com/albums/a27...-Annotated.jpg

DR650 Side Luggage Racks, Rear Plastic Guards, DR 650 | eBay UK

These side racks are all you need for soft bags and keeping of the exhaust.

Really helpful stuff, but I need to keep weight to an absolute minimum for the flight, so buying a rack here in UK is pretty much a non starter unfortunately.
I'm hoping I can do something like pics 2 or 8 in post 167. This way I can do the L bend at the top of the bracket (where it bolts to the frame) and do the rest when I get to the US.
RideFar, your solution may also be a good option for me, as again I can do some of the work before I leave home. Especially as it looks like I only need a stand off on the exhaust side. The main difficulty is of course that I have only a WR250 here in UK to get an idea from and this is no help with actual measurements.

Pinball1008 - You indicated on the bike pics that you have the Pro-Moto Billet rear rack. Have you considered something like the following from Procycle to keep your bags off the exhaust?

I can't seem to paste in a picture for some reason.

Suzuki DR650 Parts, Performance, & Accessories - ProCycle

Add To Order
Add-on saddlebag guards to protect your saddlebags from the exhaust pipe and rear tire. Requires the Pro Moto Cargo Rack (see above) to mount properly. Made from CNC machined 6061 billet aluminum. Requires some simple drilling to install. Approx. 7" wide and 9" long.

I have now decided to go a different route and will strap a Kriega US30 on the back.
I have cut my gear down to an absolute minimum and as we're staying in motels overnight, I will wash clothes every 2/3 days.
We pick up the bikes in Helena on 27th August and the 3 of us hit the CDT at Roosville on the 29 August.
If anyone wants to buy a month old DR650 in Phoenix around the 22nd of September, please let me know.

[QUOTEhttp://i8.photobucket.com/albums/a27..._Annotated.jpg=Ride Far;339563]Not a difficult job but requires some finessing and bending in a vise, especially for the mount above the exhaust, at least the way I did it. You can see the brace in this pic.

\

Here's the other side for the heck of it.

http://i8.photobucket.com/albums/a27...-Annotated.jpg[/QUOTE]


Nice setup! How are you finding the front springs? did you go for a stiffer spring? I'm looking to set mine up for a larger tank/ more weight as well, and am looking for feedback on the best suspension setup. Lots of options out there, which is great - but also makes the choices more difficult.

I tried to emulate some of these mods with our DR's. This bike is set up really well. After adding the Safari tank on my bike, I upgraded to an Elka rear shock, heavy springs & oil together with a folk brace and was very happy with the way the bike handled.

If I had to do it again though, I would skip the Safari, wasn't really needed and would have gone with the IMS which my wife had on her bike. Very adequate.
Daryll

I got the maximum strength Eiback front springs from Jesse at Kientech and they worked well. I wouldn't go with anything less than maximum strength running a Safari tank and running lots of corrugation / rough stuff.

Safari tank
 

The Safari tank is great. Not only does it hold a shit load of fuel but also provides a comfy foot rest!

http://farm8.staticflickr.com/7197/6...213caaf561.jpg

Not much action on this thread in nearly 3 years. :helpsmilie:
Recently came across a ride report on ADV Rider featuring 2 DR650's:
Earth's Ends: Riding DR650's from End to End | Page 31 | Adventure Rider

And their build thread:
When a project gets out of hand: Building two DR650 RTW bikes | Adventure Rider

Fairly extreme DR build ups on link above. Some "improvements" now coming back to bite!:rofl: No wonder, with so much unnecessary weight and bulk added! doh

But fun picks and Africa riding tips. Too bad they're not posting here on HUBB! :(

DR650 up date:
Now at 65,000+ miles (90K km), my '06 DR650 is still going strong but probably could use a top end job (valve guide seals allowing occasional smoke on start up), suspension freshen up along with some new bearings would help.

I've learned a lot from the DR Riders forum as well as the BIG DR650 thread over on ADV Rider in Thumpers forum. All good guys with tons of info and help for anything DR650. :D:D:D:D

I have not changed much on my bike in the last 30K miles. Now running Yoshimura pipe, Wolfman top duffel bag and inexpensive Nelson-Rigg soft panniers, plus awesome HID headlight. Shorai battery coming soon.

Several long On Road and Off Road trips since last update. All good. I did dent a wheel in Baja. (I have spare wheel but don't really need it)

bier

Dr650
 

I just got a DR650 , my wife and I will prep both our DR and I have to say that the post on this tread are very useful. We plan to use it for an Africa/Europe trip on 2 bikes/up ...:mchappy:

Thanks Hendi, glad to provide a few useful tips!

I wrote a lot of this thread years ago, I made quite a few mistakes in my early mods and advice I gave about the DR650. Sorry!

Like all of us, I've learned A LOT about the Care and Feeding of the DR650 since 2006 when I first bought the bike.

No one was more surprised than I to see just how good the DR is and how tough it is and how long it can go ... over 65K miles on my bike.

I should go back and edit out my errors ... but I'm lazy and it's a bit of work to do that! SO! if you have any questions about anything, just pipe up and I will try to clarify and correct. I've learned SO MUCH since early days.

Good luck on your prep! I wish I could ride along with you in Africa. Nothing like an experienced Africa expert/guide to make it more fun!
bier

Dr650
 

Thanks a lot I appreciate the offer . So far I ordered 5.3 gal tanks , new handle bars , skid plate handguard ( I prefer it to the 6.6 Gal and will carry a kolpin for use in specific area), I will do a corbin or seat concept and we are looking at soft luggage to keep the bike very light. The bikes are jetted well and still have oem exhaust ( heavy but quiet). A friend of mine (john from ADVmonster )gave me some h4 led light and they work perfect. Suspension look like is going to cost a bunch but will be worth since the bikes were pretty cheap to start with.

Good choice with the DR's Hendi, I highly recommend Cogent Dynamics suspension, some DDC valves with heavier springs in the front and their excellent rebuilt shocks. I have not touched my rear shock since 2010 and since then it has been around SAmerica 2up with luggage and lots of backcountry rides here in Canada, my buddy Nevil rode his DR RTW with the same shock with no issues whatsoever (he runs Ricor Intiminators up front)

I like the Safari tank, it was handy in SAmerica with fuel strikes in Argentina we were able to carry plenty of gas, but off road when full it is too big and heavy, it also ruins the turning lock which has caused me a few issues trying to turn in tight spaces. I am considering buying a smaller Acerbis tank for the backcountry rides I am doing now, I will keep the Safari for long trips though.

Thanks for the tip I came back from south america after over a year on a dl650and the bike did great but was very heavy while doing tough off road. Anyway 48000 miles of fun was worth the effort. For Africa light weight is what I want so the dr is perfect . Soft luggage will save a lot of weigh and the 5.3 acerbis will do well for me. I plan to set up my foot peg for gas and water . Keeping the bike more stable and agile than with the safari tank.