DR650 Expedition Build RTW 

For adventure build I always pre-route a spare clutch cable with both ends shrink wrapped. Cable breaks, 5 minutes and you're back in action..

You have an eye for engineering. A work of art!

I think that is the nicest looking fairing I’ve seen for the DR650. 👍🏻

On a bet (and because I wanted to), about 10 years ago, I took my DR650 on a brutal enduro ride. I mean like an actual old school enduro course. Giant boulders. Extremely steep hills. Muddy water crossings with straight up and down banks. Then when I was done, I cruised at about 70 mph back to our camp. I had a much lighter aftermarket exhaust (jetted to match), aggressive tires, aluminum skid plate and went down 1 tooth on the front sprocket. That's it. The machine is a beast.

I just bought a new 2024 DR650 yesterday, I look forward to making improvements to it. Your bike looks awesome!! Great video!! Happy travels!!

This is amazing, exactly how I always dreamt of building one of my own someday. Can't believe you're saying looks aren't a big concern for you when your bike ends up looking this clean, practical, robust, and just overall very very attractive. Great build, you're living some people's dream man, really looking forward to some trip videos with this thing.

Those removable signal lights are ingenious.!

That is literally a dream bike... That's it I'm going out and buying one

You'll be able to go round the world several times on that machine with total confidence and in comfort and without breaking the bank. Many years ago I toured Europe on a 650 Kat. Nothing special but I still have fantastic memories of the trip. it's all about the journey.

Really like what you have done with your DR. Watching with interest as I am considering moving from my africa twin. Thanks for sharing.

Greatings from Canada/Poland ! Good job Sir! Waiting for on-road travel !

Awesome bike! Just starting to modify my 2023 white 650. Thanks for making this.

I really like your horse! She's very nice. 💪🏼 Thank you to share! Hi from Montréal!

Very nice video and I think your philosophy is spot on. My only wonder is why there aren't more folks with this view of simple and reliable is the best. Kudos to you for your mechanics skills also.

Lots of great ideas, just a couple more for if your interested. I fitted a DRZ 400 clutch perch with a shorter lever, the shorter lever is great for 2 finger use and the clutch perch is a split type so if it gets broken it is easy to replace unlike the DR type which is one piece and is pain to swap because you have to remove and replace the hand grip. Also a good idea to bypass the side stand cut out switch, they can be an issue on rough ground, mainly when the side stand pivot bolt wears a little and the side stand can bounce a little causing the switch to cut the engine. As for gearing, stick with the 15 front, a 14 can cause accelerated wear on the chain guide / swinging arm protector where it wraps around the pivot point, a 14 creates less clearance between the chain and the pivot. Try also a choke knob arrangement where you do away with the choke cable, the cables can and will rust and seize up, any water that gets in the left switch block will go straight down the cable, there are a couple of different types, one is just a small plunger type that screws straight into the carb and sits between the cables, it can be a little fiddly to get to, or the other is a shorter cable type that is mounted just under the carb, it points down and will not collect water. The after market Cush drive rubbers are a good investment, they tend to last a lot longer than the factory rubbers, when the rubbers get softer it puts more stress on the Cush drive bearing causing the bearing to fall apart, keep an eye on that bearing they do play up a little. Swapping over to the lower chain roller to one with a bearing is a good idea, the factory one just runs on a steel bush and get gummed up with mud and grit , you can also remove the top roller and just replace it with dome head bolt, there are stories of guys that have had the rollers ripped out of the frame but that could be from larger rear sprockets changing the angle of the chain when the suspension is fully compressed. The old DR is a hell of a bike, so safe travels and enjoy.

Got to love the DR 650. Cool video mate 😎👍

Great stuff. Bing watching your videos here in Austria. With your help my girlfriend opted out of a tenere and is now all in in the DR-gang :) Thanks buddy.

Great looking dr, love the mods.

Fantastic Vid Sir👍 You have got it figured out imo. That DR is a Solid machine. Hoping to do a similar Expeditionary upgrade to my Honda XR400.

Thanks for sharing I really wish we got the DR650 over here in the uk :)

Awesome build. So many parts i had nvr seen. Lol its odd i dont have the bike yet but im planning. Thanks

Thanks for bringing all these tips to us. Was all set to go for another brand but complexity of EFI and water cooling has me thinking stay with the basics. Just need to figure out new or used and where. Thanks.

Awesome build! Everything looks perfectly picked out for what you need it to do! Cool for me (a Canadian) to see some Canadian parts on Aussie bike... Although I was riding with a guy last year who had that ferring on his 701 and it did not survive being dropped while off roading. They seen a little fragile compared to some of the more expensive options. look forward to seeing some epic adventures on this machine!

That's a sweet DR650!! I only ever did the safari tank, bash plates and barkbusters on my old DR. This is a whole other level. The stock suspension IS pretty bad. Upgrading the suspension is totally worth the money and I wouldn't hesitate to do it if I get another DR. This is definitely one of the absolute best RTW machines.

Very thorough. I’ve done all those mods except the Brittania which I do have on a WR250R. LeoVince exhaust with pro cycle carb adjustment. Lighter, quiet peppier. I’ve put about 8000 trail type miles with no mechanicals. (TAT and BDR’S here in USA) I did put a different front fender on too. JD ADV channel…

I have a 2021 DR650 I bought new. I have most of the mods you have, all very practical. I installed a 14 tooth front sprocket almost immediately after buying the bike, and would highly recomend it to anyone with a DR. Bikes are all a compromise when wanting them to be ridable both on road and off. I personaly would like more low end torque and less speed for off road, but still want comfortable speed and performance on the highway. I feel the 14 tooth front speocket was the best compromise option. Greaat bike, bit tall for a short legged guy like me, but love it.

Excellent work , she looks sweet . I do miss my 2019 DR650 but I live where you are better off with a bike that can do 80mph easily and for longer times ie freeway and highway speeds . Some places are 2 to 5 hours away just to hit any legal dirt and having semi trucks pass me is not an option unfortunately . You have more knowledge and electrical skills than I do about engines etc but I really wanted to learn with that bike . I changed the battery to a lithium battery changed the rear brake light to an LED added Thumper Jockey pod lights and put the ADV double take mirrors on my bike . Didn't get to the fuel filter yet or the LED headlight . I saw the 2020 Africa Twin and then the Tenere 700 at 5 grand less and was very intrigued . Then after reviews and videos of riders loving it I went with the Tenere . Not being rich I just had to let the DR650 go , really liked having the 2 bikes but 2020 and the devastation it had on my business left me no choice .

🇦🇺😎👍The big DRasauras . .. that tail pipe weighs a ton and it stifles the performance….brakes , lol . Say no more…I played with the sprockets and for road riding you can’t improve on the ratios from the factory. I’ve replaced at least 10 sets of sprockets and chains on both of my DRs. Sounds like you are on the right track mate. Love that horse 🐴

This is what I want to do. I live in a wet enviroment the auto chain oiler is key. Your DR 650 is what I want to build.

What a build! I like it!

Only thing left to do is that 790 big bore kit and OS valve head! Ive always wanted to build one of these. Looks great! The fairing is 🔥

Solid looking rig mate, but let’s get it dirty!!

The DR650 has an O-ring chain as you know, so the internal link pins are fine without oiling it. But yeah, the outside link rollers do need lubrication. Like you said, adding oil, then riding in dust and dirt makes it like a gritty paste that will wear out the outer rollers and pins, and the sprockets too. So, have you ever thought of using a dry graphite lubricant on the chain? That's what I've been using for years, with great results. By the way, your DR650 looks really, really good!

fantastic mods! would be nice if you could list them in your description 👍

I used to be in the same camp as you about the exhaust. I didn't want to make my Dr any louder, and most aftermarket mufflers are way too loud. Eventually, I took a risk and installed the Leo Vince x2 Enduro muffler from procycle. It isn't very much louder than stock, sounds a bit better, but most importantly it gave me way more access to the torque and power on the Dr! You really are missing out on a lot of good power if you keep the stock exhaust. Mine pulls way harder now, even from low rpms. When I added an oversized header pipe a while later it helped increase top end power a bit, but the muffler made the biggest difference

Nice build sir!

Nice bike!

Equipou ela toda ! Parabéns! Manda fotos da viagem que fez com ela........

Nice build!

Looks clean. Go ride! Oh yeah, delete the side stand safety switch. In rough conditions, the kickstand bounces under its own weight and will cut power. Likely when you need it most.

Hey! Great video! Surprised you kept the stock exhaust since it’s really heavy. Great build!

Still waiting on some more of the dr man

On some bikes, smaller front sprocket may cause the chain to wear the plastic guard on top of the swing arm. A larger rear sprocket might be a better option.

Greetings What a fantastic detailed video. Would you provide us with the links to purchase the mods. Keep producing more videos 🇺🇸🍾🎉🇺🇸

Nice bike !! I noticed that your front brake line is routed on the outside of the lower fork. It's supposed to be inside, between the fork and wheel. On the outside it can easily get damaged in a fall or caught on something.

Great bike build. It looks amazing and very usefull. Do you have a list of the parts you bought and links?

It would have been nice to put links in your description for some of your mods. I live in Canada and run a DR650 and after a lot of research over the last year have never come across that "made in Canada" fairing . I also have never seen those plug in signal.lights; what a great idea.

Great video and beautiful DR build. Would you like to share links for items installed on your bike please ?

Put a GSXR exhaust on there mate! It's heaps lighter and less restrictive. And still a Suzuki factory part!

Suggestion- a drop down center stand ( comes in handy when working on the rear tire area ) holds the bike up with out leaning it !

FYI mild steel sucks it week and heavy, cromoly steal hug improvement and easily welded. Please leave the cluck safety on its enough to be aware how it fails it's easy to bypass any where or time. Great bike.

A very nice DR! Would really like to see links for all the mods and total price for all the work. Not a spec of dust on that bike lol.

Good video. Small technical point: You don't use "volts" (you use power but voltage is a reflection of that - you also need to know amperage draw to know how much power is being used). To measure actual power (watts) being used requires a much more expensive inline meter - not something you'd ever install on a bike like this). I doubt the voltage meter will show much other than the charging system is working or it's failed. The reason is that when the bike is running the voltage regulator (part of the stator and charging system) will always try to keep the voltage correct no matter what the draw is. The volt meter is not a bad thing but just not that informative, in general. If you see the voltage dropping, you know the charging system is failing and you better sort it out quickly.

Great Job with this!! Tastefully done. Really like the front end treatment, but all the other mods blend together nicely. How the heck dod you gwt the bike so clean??

if doing any deeper water crossings i'd also swap the rear brake like switch for a hydraulic brake switch... is a pressure banjo bolt dealy.. and sealed... goes into rear master... one less thing to fail..

In the comments you said you have a UFO front fender. Which one did you get? They have so many. I really like your bike. It’s well thought out. Very clean and flowing, not cobbled together.

great video and great bike, can you give the link for the blinkers

The bike came out great. All very functional extras. What tires are you running and how do you like them? Thanks

Sooo.... When can we see the first adventue?

That bike is super clean. Must've taken ages to prep it for the video.

Could you add a mods list with product names in the description? Thank you from Dallas

If you want a lighter muffler that is still quite have a look at the DG RST slip on muffler and mid pipe.

@Iron Horse DR650 what brand are those plug in rear LED indicators? Great idea 👍🏻

Greetings from Canada. Looks beautiful! Can you please name the company of the front fearing? And was it easy to install? Thx.

Bike looks great. One question there's only 3 boots on top of the shelf. What happened to the forth boot?

nice bike, looks like its never been ridden, for what you've spent you could buy two t7's :)

👍👍👏

That faring is the most beautiful fairing I could find for this bike but I can’t justify paying 1000 dollars for it 😂

Always carry a spare extra large kick stand platform for seriously muddy ground

What's the make and model of your Fairing/ Windscreen? Thanks

Great video and nice bike. Mine is white just like yours. Apologies if someone already asked…..is that the ProCycle tool tube and mounting straps? I’ve faffed around trying to make my own but I think I’m ready for an off the shelf solution. Thanks!

Hi, is this the R, S or High Output Lynx Dash/Fairing? Looks awesome!

Do you have a link for the turn signals please?

Do the muffler mate Big performance upgrade

looks you got the "LOW Comfort" seat, what cover option do you have and why? all carbon fiber or carbon side/gripper top.

Great build. What brand are the plugin indicators?

Where to buy (link) the removable flash lights, please?

What headlight and dash board is that?

Hey guys. What’s the name/manufacturer of the fairing?

did you add the fork clamps or did it come with that thanks ?

Where's the other boot? I see 3 on the shelf.

Красиво смотрится😀

Who made the fairing?

Needs a third wheel for an honest expedition. More carry ability. Russia had those to carry anti-tank missiles, a hard-point to hold machine-gun, and two armed soldiers addition to the operator. Oh, and it has a reverse gear,

Bigger foot pegs is a must for me? I have to assume you’re going to do that if you mentioned it in the video I missed it sorry

The turn singles are the ticket!

What company makes that front fairing?

Haling around that super heavy pipe will likely break your bike a super bike pipe is what you want the frame will now support more luggage

Those fork boots look shorter than stock. Are they aftermarket?

No suspension mods?

What tires do you have?

Mine stalls on the freeway, and its pissing me right off.

What is your front fender?

🇦🇺😎👍Scenic Rim Sth east qld

The Philadelphia police force use it too.

We don't want to look at you just the bike.

Looks like you need to ride way too clean for a DR650 wow ride it this bike will do alot of stuff not just look good clean chain is new. Plastic chain guide hasn't been rubbed other than chain being installed. Prove the bike is for riding not for bike show!

Great built!!!! I have one old XF 650 Freewind (same than Dr650 but less off-road oriented) that I bought few months ago with 97000 km and still looks really good. Agree with you that is strong and cheap. I’m sure will bring you lot of happiness. Did you buy brand new in Australia? I’m from Spain, and in Europe we haven’t in catalogue.(anti contaminations restrictions) Do you have instagram or Facebook to follow your trip?

The Cogent shock transforms the DR