Here is the pre-1996 fuel tank mounting hardware adapter from Zen Seeker's Suzuki DR650 Resource Site. http://dr650.zenseeker.net/GasTank.htm I got the FMF exhaust system, FMF Q-4 and FMF header pipe, and 6.6 gal fuel tank in over the weekend. I was gone all weekend but will assemble tonight and post photos.
Maybe you know it by another name. Mattawa or Desert 100? Stumpjumpers MC Desert 100 Race, Poker Run and Dual Sport The rubber starter relay holder slides onto the two spades pointing at us. The rubber headlight fuse holder slides onto the one spade on the right pointing up. Looking straight at the bracket. It's pretty ugly without the relay and fuse in place.
The stock DR650 seat is a 2x4. If you intend on replacing it and care anything about the weight of your bike, do not get a Corbin. The shot fiberglass pan weighs a ton. One point of many but that's the end of this Corbin rant. Renazco seats use the stock seat pan, are light weight and beautifully hand crafted. The lead time is really long, but the wait is worth it. Local no shipping bonus, Chris Hickson is in Ravensdale! Sargent makes a DR650 seat that I've heard good things about too. On their website they say they have, "Our own lightweight PolyTec seat pan". Haven't seen one for the DR but I have a Sargent for my R1100GS and the quality is quite good. The base models are "roughly" the same price for each brand.
I have installed the FMF exhaust system with the Q4 muffler on the bike. <a href="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/11739799_GxLXk#829328171_CchC6-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/CIMG0383/829328171_CchC6-M.jpg"></a> <a href="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/11739799_GxLXk#829328161_UtLky-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/CIMG0382/829328161_UtLky-M.jpg"></a> <a href="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/11739799_GxLXk#829328228_tLmmc-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/CIMG0387/829328228_tLmmc-M.jpg"></a>
I was also able to prefit my Acerbis fuel tank. <a href="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/11739799_GxLXk#829328277_LsNcr-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/CIMG0391/829328277_LsNcr-M.jpg"></a> <a href="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/11739799_GxLXk#829328293_H7XSc-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/Steves-BMW/CIMG0392/829328293_H7XSc-M.jpg"></a>
I fitted the seat to the tank tonight and installed a SW-MotechBash Guard / Skid Plate. This is a great piece of armor. The seat did not fit my new tank very well. <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881587_XE5kq-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0399/830881587_XE5kq-L.jpg"></a> I am on a limited budget so I modified the stock seat to fit the pre 96 tank on this 1999 DR <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881635_enjHx-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0401/830881635_enjHx-M.jpg"></a> verified the fit <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881660_MBy8G-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0402/830881660_MBy8G-M.jpg"></a> stapled things back together <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881685_gvkGL-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0403/830881685_gvkGL-M.jpg"></a> and had a great fit <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881704_M78AS-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0404/830881704_M78AS-M.jpg"></a>. I also got my new SW-Motech Bash plate. It was the most expensive one I found (125.00) but for the protection it will provide I think it is the best on the market. It attaches to the frame and protects like it should. You get a new FWD lower engine mount bolt. <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881497_d2ef3-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0394/830881497_d2ef3-M.jpg"></a> <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881522_jepzd-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0395/830881522_jepzd-M.jpg"></a> looks great on the bike. <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881832_FJnim-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0410/830881832_FJnim-M.jpg"></a> <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881788_GWnpd-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0409/830881788_GWnpd-M.jpg"></a> <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#830881769_M56kT-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/CIMG0408/830881769_M56kT-M.jpg"></a> It took 1/2 hour to fit the seat and 15 min to install the bash plate.
The oil cooler has been modified to the point that I can not use it. Before I buy a new used cooler, do I really need one? How much warmer does the bike get with the oil cooler holes plated off? <a href="https://steve-b.smugmug.com/Motorcycles/DR650/11695391_Sywf2#825845024_Pdi8i-A-LB"><img src="https://steve-b.smugmug.com/Motorcycles/DR650/hacked-oil-cooler/825845024_Pdi8i-M.jpg"></a>
Hooked up the fuel and started the bike. Running lean, idles nice but backfires and pops when I exercise the throttle. At 4 1/2 turns of the air needle runs better. Thinking that I need a larger jet.
Yes, you need the oil cooler. The DR is air/oil cooled. That oil cooler is a big part of the cooling system.
Other than installing a new oil cooler and manual choke the bike is assembled, starts easily and runs OK (the choke seems to hang so it runs rich) and is begging to go for a ride this weekend. one minor issue the tail light does not work. Blinkers ok, brake light ok, headlight ok, tail light :-(. Here is what I have done and invested so far. Bike 1999 craigslist DR650 bike in a box $500.00 (everything but the engine had been torn to pieces, hacked apart and thrown in a big box) I was very worried at first and thought I had made a mistake. After buying an e-service manual and parts book everything became a game kind of like a 3d jigsaw puzzle. New tank Acrbis 6.6 234.00 oemcycle free shipping FMF header and Q4 exhaust 430.00 oemcycle FMF sale tires 40.00 craigslist new wiring harness, air box, battery box 65.00 ebay air box mod, dynajet carb kit 49.00 ebay skid / bash plate 125.00 sw-motech oil cooler 18.00 ebay 14 tooth sprocket 16.00 seat mod, rhino liner on fender and side plates 30.00 myself manual choke 22.00 roughly 1000.00 for a total of 1500.00 I am pleased with the cost and how everything turned out. Still to come front fork springs, rear shock spring 230.00 Kientech
Looks great! I can see how it might have felt overwhelming at the start, but $1500 total for a low mileage 99' is a steal.
Steve, You forgot a line in your price breakdown: "Two weeks of frenzied labor and busted knuckles...... Priceless" Your bike looks great! Cheers, Harry
Don't want to piss in your cornflakes but that plate is actually one of the worst, it's too thin to provide real protection. I have seen a busted case where a rock punched through the aluminum, which doesn't happen with the other skid plates on the market. Other than that, nice work on the bike. You definitely got more than your money's worth!
Well I feel foolish. Looks like I will need to get another aluminum plate welded to it to beef it up. Just looked to cover much better.
That is exactly what the other guy did after he punched through his. The pictures are somewhere in the long DR thread. If you are going to ride it in the rocks it might be worth doing it now. Definitely a lot easier than fixing a hole in your cases.
I also have the SW motech plate on my DR 650, it is the only one that I thought was mounted properly. I do feel that the aluminum is a little thin and the older design falls short in that the rear mounting bolts head stick out where I mush them. The Newer SW plates address this I have been told. These are outstanding plates for flying debris damage and even for medium groundings on most any object. Hard smashes to sharp rocks would be a problem. My last plate was thicker and attached with clips to the frame tubes. The plate worked but my frame rails we flattened. Depends how you use your bike. The SW motech plate is very well engineered.
No need to feel foolish, many people ride their DR's using this skidplate with no problems. But if you're going to even moderately off-road your DR, then I suggest you beef up the plate. Take a look at what I did to mine... http://www.advrider.com/forums/showpost.php?p=9062643&postcount=20666
My rear shock is going to Kientech this week for an overhaul and new Eibach rear spring. Also getting Intiminators and Eibach front springs to match for the forks, seal savers, AMP engine guards and an oversized pro taper handle bar kit with 2" bar risers.
I have finally finished my bike, except for the oil cooler, and am very pleased with the outcome. All in all it has been a steal for 2150 total investment. The new oil cooler will arrive next week, I will install it and take the bike out for its first ride in 9 years.
