In August 2011, I purchased a new 2011 Suzuki DR650 motorcycle for a trip through South America. The engine, exhaust, chassis and suspension have been maintained in the original (stock) configuration. This approach was chosen to increase reliability and facilitate repair or replacement of items with original parts while traveling. The modifications were only made to the motorcycle to add durability, safety, comfort and protection. The prices listed below were the original costs of the items. The prices are listed to serve as a reference point for the cost of the build.
Stock Specifications: [$6,000]
Type: 4-stroke, air-cooled, single cylinder, OHC
Displacement: 644cc
Fuel System: MIKUNI BST40, single
Starter: Electric
Ignition: Electronic ignition (CDI)
Transmission: 5-speed constant mesh
Final Drive Chain: DID525V9, 110 links
Suspension Front: Telescopic, coil spring, oil damped
Suspension Rear: Link type, coil spring, oil damped
Brakes Front: Disc brake
Brakes Rear: Disc brake
Tires Front: 90/90-21 M/C 54S, tube type
Tires Rear: 120/90-17 M/C 64S, tube type
Fuel Tank Capacity: 13.0 L (3.4 US gallons)
Fuel Tank Capacity California: 12.0 L (3.2 US gallons)
Overall Length: 2255 mm (88.8 in), Low 2235 (88.0 in)
Overall Width: 865 mm (34.1 in)
Wheelbase: 1490 mm (58.7 in), Low 1475 mm (58.1 in)
Ground Clearance: 265 mm (10.4 in), Low 225 mm (8.9 in)
Seat Height: 885 mm (34.8 in), Low 845 mm (33.0 in)
Curb Weight: 166 kg (366 lbs)
MPG: 56 or KMPL: 20
Modifications: [$1,679]
IMS gas tank (4.9 gallons) (added 250 mile range) [$260]
Locking gas cap (added safety) [$33]
Pingel Fuel Petcock (added 250 mile range) [$93]
Seats Concepts dual sport seat (added comfort for long rides) [$160]
ProCycle wide and low foot pegs,(added 2 inches of leg space, comfort for standing) [$140]
Fly Racing tapered bar and Protaper wide bar mounts, (added comfort, control and strength) [$100]
ProCycle bar extenders, (added 1 inch in height, comfort for standing) [$33]
Moose Racing handguards (added protection for hands from brush and cold) [$105]
Suzuki spare brake and clutch levers, (added spare parts for safety) [$23]
BikeMaster bar end mirrors, (added enhanced rear view, safety and crash protection) [$50]
Moose Racing quick turn throttle, (added easier throttle response) [$40]
Skid plate (added crash and rock protection) [$80]
ProCycle engine armor, right and left side (added crash protection) [$80]
Tokai Designs rear light kit (added sleeker design and crash protection) [$90]
ProCycle fuel filters (added internal engine protection) [$4]
TwinAir reusable air filter (added internal engine protection and ease of maintenance) [$31]
BikeMaster magnetic oil drain plug, (added internal engine protection) [$12]
Ball Bearing chain roller (added safety) [$15]
Pat Walsh Designs rear cargo rack (added extra secure cargo area) [$125]
Pelican Case (added extra secure cargo area) [$150]
Shortened kickstand ¾” removed (added for more stable parking/leaning) [$55]
Crampbuster throttle cruise assist {$9}
Expendables: [$296]
Pirelli MT40 tires front and rear (2000 miles of use) [$180] - bought along the way
Chain, Front and Rear sprocket (4000 miles of use) [$110] - bought along the way
Extra Chain Master Link (added safety) [$6]
Extra spark plugs [$12]
Extra front and rear tubes [$20]
Extra clutch cable [$40]
Extra master chain link [$5]
Extra oil filter
Extra fuel filter
Valve feeler gauge
Chain lube, loctite, 1 liter of oil, tube patch kit, bailing wire, zip ties, jb weld, electrical tape, duct tape, various nuts and bolts.
Extras: [$80]
Tools [$75] - multi-tool, hex wrenches, screwdrivers, adjustable wrench, bead buddy, tire irons, air pump, small socket wrench set, spark plug socket.
Spare plastic gas tank (10 liters, adds 100+ miles extra) [$5]
Cargo net [$10]
Gear: [$3,080]
Arai XD3 Helmet [$540]
Olympia Mesh Jacket [$320]
Olympia Airglide Pants [$230]
Marmot Precip rain jacket and rain pants [$120]
Alpinestar Gloves [$80]
Gaerne G Adventure Motorcycle Boots (size 10-1/2) [$250]
Giant Loop Great Basin Bag [$435]
Giant Loop Fandango Tank Bag [$160]
Garmin GPS and Ram mount [$435]
GoPro video camera [$300]
Dirt not included… :)
For more information about this build and testing check out... The Moto.
Type: 4-stroke, air-cooled, single cylinder, OHC
Displacement: 644cc
Fuel System: MIKUNI BST40, single
Starter: Electric
Ignition: Electronic ignition (CDI)
Transmission: 5-speed constant mesh
Final Drive Chain: DID525V9, 110 links
Suspension Front: Telescopic, coil spring, oil damped
Suspension Rear: Link type, coil spring, oil damped
Brakes Front: Disc brake
Brakes Rear: Disc brake
Tires Front: 90/90-21 M/C 54S, tube type
Tires Rear: 120/90-17 M/C 64S, tube type
Fuel Tank Capacity: 13.0 L (3.4 US gallons)
Fuel Tank Capacity California: 12.0 L (3.2 US gallons)
Overall Length: 2255 mm (88.8 in), Low 2235 (88.0 in)
Overall Width: 865 mm (34.1 in)
Wheelbase: 1490 mm (58.7 in), Low 1475 mm (58.1 in)
Ground Clearance: 265 mm (10.4 in), Low 225 mm (8.9 in)
Seat Height: 885 mm (34.8 in), Low 845 mm (33.0 in)
Curb Weight: 166 kg (366 lbs)
MPG: 56 or KMPL: 20
Modifications: [$1,679]
IMS gas tank (4.9 gallons) (added 250 mile range) [$260]
Locking gas cap (added safety) [$33]
Pingel Fuel Petcock (added 250 mile range) [$93]
Seats Concepts dual sport seat (added comfort for long rides) [$160]
ProCycle wide and low foot pegs,(added 2 inches of leg space, comfort for standing) [$140]
Fly Racing tapered bar and Protaper wide bar mounts, (added comfort, control and strength) [$100]
ProCycle bar extenders, (added 1 inch in height, comfort for standing) [$33]
Moose Racing handguards (added protection for hands from brush and cold) [$105]
Suzuki spare brake and clutch levers, (added spare parts for safety) [$23]
BikeMaster bar end mirrors, (added enhanced rear view, safety and crash protection) [$50]
Moose Racing quick turn throttle, (added easier throttle response) [$40]
Skid plate (added crash and rock protection) [$80]
ProCycle engine armor, right and left side (added crash protection) [$80]
Tokai Designs rear light kit (added sleeker design and crash protection) [$90]
ProCycle fuel filters (added internal engine protection) [$4]
TwinAir reusable air filter (added internal engine protection and ease of maintenance) [$31]
BikeMaster magnetic oil drain plug, (added internal engine protection) [$12]
Ball Bearing chain roller (added safety) [$15]
Pat Walsh Designs rear cargo rack (added extra secure cargo area) [$125]
Pelican Case (added extra secure cargo area) [$150]
Shortened kickstand ¾” removed (added for more stable parking/leaning) [$55]
Crampbuster throttle cruise assist {$9}
Expendables: [$296]
Pirelli MT40 tires front and rear (2000 miles of use) [$180] - bought along the way
Chain, Front and Rear sprocket (4000 miles of use) [$110] - bought along the way
Extra Chain Master Link (added safety) [$6]
Extra spark plugs [$12]
Extra front and rear tubes [$20]
Extra clutch cable [$40]
Extra master chain link [$5]
Extra oil filter
Extra fuel filter
Valve feeler gauge
Chain lube, loctite, 1 liter of oil, tube patch kit, bailing wire, zip ties, jb weld, electrical tape, duct tape, various nuts and bolts.
Extras: [$80]
Tools [$75] - multi-tool, hex wrenches, screwdrivers, adjustable wrench, bead buddy, tire irons, air pump, small socket wrench set, spark plug socket.
Spare plastic gas tank (10 liters, adds 100+ miles extra) [$5]
Cargo net [$10]
Gear: [$3,080]
Arai XD3 Helmet [$540]
Olympia Mesh Jacket [$320]
Olympia Airglide Pants [$230]
Marmot Precip rain jacket and rain pants [$120]
Alpinestar Gloves [$80]
Gaerne G Adventure Motorcycle Boots (size 10-1/2) [$250]
Giant Loop Great Basin Bag [$435]
Giant Loop Fandango Tank Bag [$160]
Garmin GPS and Ram mount [$435]
GoPro video camera [$300]
Dirt not included… :)
For more information about this build and testing check out... The Moto.
