Warp 9 Racing - The Best Wheels In The World

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NOREN FILMS / 12 NEW RIDING PRODUCTS / PRESERVING OFF-ROAD ROUTESPicks for Your NextRTW TripVIKING BIKINGNorway on anAfrica TwinARE ACCIDENTSINEVITABLE?SUZUKI’S DR650TRANSFORMED!Two Kinds ofMotorcyclistsFrom Dual-Sportto Enduro TourerMAKING ACOMEBACKNew HuskyStreet LegalsALONE WITH ABROKEN LEGMishap on theMosquito CoastMarch/April 2015Overland ExpoBash in the BlueRidge MountainsRiding NewfoundlandThe Trans-CanadaAdventure TrailScan for a FREEdigital back issue! 5.99 US / 6.99 CAN

ConvertingPROJECT BIKEOhhow we love to tinker,modify and attempt to improveour ADV bikes. Out of the box, Suzuki’svenerable DR650 is a relatively pedestriandual-sport, not particularly suited forRTWing or schlepping a rider with lots ofgear across continents. But with a littlehelp from the aftermarket and somewrenching skills, that can be remedied.Project Bike 1So why consider a motorcycle that’s been more or lessunchanged since 1990? ADVMoto keeps tabs on bikes thathave made their way around the globe, and a good number ofthem are Suzuki DR650s—there must be a reason. Put it downto a minimalist design that’s proven to be both highly functionaland reliable: air-cooled, single cylinder, single-carb, mechanically simple and easy to repair (or bodger fix in a pinch) with easyKawasaki’saccess to new and used parts anywhere in the world, relativelySuzuki’s DR650, like thed for ages. Butlightweight, uses low octane fuel, gets 50 mpg, sells for a bargainKLR650, has been arounis known as an( 6,000– 6,500 new and 3,500– 4,000 used), and is supportedunlike the KLR, which650 follows moreby a HUGE aftermarket. And one more thing—it’s actually fun toadventure bike, the DRe. DR650s are aride on- and off-road.of a dual-sport heritagse riders whoIn some ways the DR650 is comparable to the ubiquitous Kawasakicommon choice for thorica, Australia orKLR650, but its far more off-road worthy, and also has a reputationwant to tackle RTW, AfBut, stock bikes arefor being one of the most reliable bikes ever built in its class. To some,South American trips.difications.simplicity is the bike’s strength, especially if the idea of dealing withseldom used without moa sophisticated onboard computer network isn’t your thing—not tomention the potential of costly repairs of a more complex bike that,alone, could easily eclipse the purchase of a DR.If there’s an issue with the DR650 it’s that it’s disguised as a dual-sportrunabout that, at first blush, has little appeal to the adventure crowd.You could say that the only thing wrong with the DR650 is that Suzukinever got around to re-packaging this extremely worthy machine forlong distancing. Although that’s a pity, it’s also an opportunity. With sucha brisk aftermarket making everything imaginable for this bike, you caneasily ruggedize and customize the DR into one of the best generalpurpose adventure bikes available anywhere—and still save a bundle.34March/April 2015

into iruEndruo Toby Paul H. SmithProject Bike 2We’d like toespeciallythank Suzukiand theaftermarketcompanies whocontributed tothis project bikefor their supportof the “Lost fora Reason” (AKA:“LFAR”) charity.ADVMoto hasbeen behind it allthe way, and it’sfast becoming theNorth American ADVcommunity charityof choice.LostforaReason.orgAdventureMotorcycle.com35

The LowdownThe good folks at Suzuki HQ provided a stock donor for this project withthe idea of ADVMoto transforming their dual-sport into an adventurer.However, we intentionally left the engine alone, and concentrated onstrengthening the rest of bike for the roads of the world, long distancerider comfort and carrying capacity. Although there are plenty of enginemods available, it’s so ridiculously reliable we didn’t see any need to alter it.We’d also like to thank Suzuki and our aftermarket sponsors who gotbehind using the project bike to increase awareness of Ron Grace’s “Lostfor a Reason” (“LFAR”), the charity that’s so popular with North Americanadventure riders.We ended up doing a lot more to the bike than was necessary toaccomplish the goal of making it ADV worthy. However, this “kitchensink” approach will at least give you some idea of the many upgradeoptions available.The SeatNo secret to DR650 riders is the necessity to replace the stock seat. Likemost aftermarket parts for the DR, there are many options. We went withSeat Concepts because of their exceptional quality, inexpensivereskinning kit that transforms it into an all-dayer.ADVMoto spent a year tryingout and testing a large arrayof modifications. The ideabehind this project bike wasto experiment with differentaftermarket products todetermine the best waysof improving on therock solid platformof Suzuki’s DR650.Read our reportand decide whichmodificationsare most relevant to you.March/April201536 36March/April2015Seat Concepts’ Robert Lightfeldt does the heavylifting for a reskinning over a stock seat pan. Forlong distance riders, an improved seat is a must.The folks at Seat Concepts provide an extremelycomfortable and durable, yet inexpensive solution.Project Bike 3

Gas Tank & FairingThe stocker gas tank holds about 4 U.S.gallons. That’s not bad, but typically runsdry before 200 miles. Amongst the upgradesavailable we liked Safari’s design the bestbecause of its construction, weight distribution and capacity ( 8 U.S. gallons). Anotherreason is Safari’s rally fairing that bolts ontothe tank, effectively moving weight off thehandlebars and extending the windscreenfarther away from the rider. The stock windscreen is attached to the handlebars and tooclose to the rider, tending to “punch” the riderwhen standing. Safari’s rally fairing also givesyou a dash to add gadgets, aux lighting andcontrols, as well as room to mount a muchmore effective windscreen. And that’s whereMadstad Engineering joined in, by customdesigning a windscreen and mount, as well asetching the LFAR and ADVMoto logos onto it.Madstad’s large windscreen upgrade significantly reduces wind/rain buffeting.Also stepping up to help get the word out onLFAR was LA Car Wrap. Safari’s fairing comes “inthe white” and required a paint job. Our friends atLA Car Wrap gave it a very cool industrial-strengthmakeover while adding to the bike’s visibility.Project Bike 4Armor, Racks and Luggage SystemOne of the big debates these days is whether to gowith a hard or soft pannier option. We went withsoft for several reasons: On a world trip the bikewill often be dropped and soft bags make superior “landing cushions.” Unlike aluminum panniers,they don’t need to be pounded back into shapewhen dented or crushed. And with the DR’s shorterframe, it’s easy to get an ankle wedged and mangledbetween a footpeg and an aluminum pannier. Wewent with Wolfman Luggage because of many yearsof prior experience and the rugged versatility of theirproducts. Because fuel capacity was covered, theother important liquid is water, especially for extendedcamping or long, hot climate rides. For this, Wolfmanincluded an adaptable rack bracket and the innovativeRotopaX system—allowing one or two gallons of aquato be easily stowed. The racks were another matter. Itwas difficult to find a well built and sturdy set. Plus, weneeded a system that would work well with Wolfman’sRocky Mountain Saddlebags. Barrett Products in Australiaimpressed us with their armor-like quality that substantially strengthens the rear end of the bike. AnotherAustralian firm, B&B Off Road, supplied us with theirtough and extremely well made skid plate, BIG rearrack and side frame armor.Above On the road testing along the Central California coastline. The DR’s transformation into a comfortable long-hauler wastruly remarkable.Below Many of Paul’s mods were to better accommodate hisheight when standing on the pegs.AdventureMotorcycle.com37

SuspensionThose who’ve followed my reviews in the past knowmy pet peeve. Until recently, most bikes came withspongy, soft, and pogo stick-like suspension thatbegs upgrading. We put out the word and EPMPerformance Imports came to the rescue with theirHyperpro line of monoshocks and progressive forksprings. Their monoshock made all the difference inthe world to rider comfort and the handling of theloaded bike. And a simple swap of the fork springscured what ailed the front end, too.Wheels and BrakesAbove EPM Performance Imports’ Hyperpro rear shockmade all the difference in the world.Below Warp 9’s heavy duty rim and spokes, withenlarged brake disc available with/without the DR’sspeedo mechanism in the hub.Although stock wheels do the job, dented and warpedrims, as well as broken spokes, are common on longtrips. Tougher rims, bigger disc brakes and strongerspokes are expensive upgrades, but worth considering.I’d never worked with Warp 9 Racing before, but I wasduly impressed with their quality and craftsmanship.Warp 9 also supplied a brake and chain armor as well asother important components (see below).The lesser known tire company, Vee Rubber, has beena loyal sponsor of ADVMoto since we returned to a printmagazine a few years ago. They allowed us to sampleseveral of their offerings to determine which tires wouldbe best suited to the task ahead. From full knobbiesto 80/20s they got us through some of the toughestenvironments that even extensive testing in Death Valleycould throw at us.Project Bike 5Controls and DashMost of the steering and dash componentswere modified to support easier standingup and improved instrumentation.March/April20153838 March/April2015I’m a tall rider, and was determined to work stand-upriding comfort into the redesign. Twisted Throttle, ProCycle,and Warp 9 joined in as solution providers. Bar risers wereprovided by Warp 9 and Rox Speed FX to push the standing height limit. And we added Pro Moto Billets’ FastwayAdventure footpegs (prototyped on our bike), along withProCycle’s footpeg mount lowering kit, to transform the DRinto THE most relaxing and controllable bike imaginablefor off-the-seat riding.Twisted Throttle supplied Barkbusters VS handlebars andVPS handguards as well as a set of innovative AdMore LEDturning light strips that attach to the handguards. We alsoadapted their Denali D2 winglights to the Safari fairing, providing an extra measure of night riding and oncoming carsafety. Meanwhile, we used Warp 9’s clutch and brake leversfor a more comfortable feel and shorter throw.On the gadget front, Trail Tech supplied their Vapor gauge,replacing the rudimentary instruments of the stock bike.Beyond an option, the Vapor supplies other much-neededdata such as tach, engine temps, and more. And Black DogCycle Works provided their rugged throttle control to easehand cramping on those long slab riding days.

Other GoodiesAnyone wanting to mod their DR needs to start theirproject with the guys at ProCycle. They’re DR specialists andTHE resource for many invaluable upgrades to our projectbike. See their list of components on the accompanyingtable. (ProCycle also supplied an industrial strength clutchand pumper carb to be the subject of a future review.)A must-have component is the SuperBrace. It stabilizesthe bike’s forks just above the fender and man, does itimprove the bike’s ride! And, Twisted Throttle providedanother option that I wouldn’t go without—a centerstand. Even though it adds weight and can get in the wayoff-road, it just makes maintenance and bike loading/unloading so much easier.Racetech Electric’s resident genius, Evan Grist, rebuiltthe DR’s stator and supplied a bigger regulator to support extra lighting, gadgets and heated clothing. The newdash provided room for adding switches, power ports andlights. But that also meant plenty of extra wires runningeverywhere (something we’re still trying to neaten up!).Twisted Throttle’s PowerHub2 took a little finessing, but wesqueezed it in under the seat. Without their hub the battery would be a rat’s nest of wires. Speaking of batteries,our longtime supporter Shorai, came through with a solidstate battery and a special computerized charger. I’m theirNo. 1 fan and have been using their batteries since theyopened for business, and wouldn’t go back to a lead-acidstyle for any reason.Barrett also supplied one of their substantially smallerand lightweight replacement exhaust canisters. Anotheroption I won’t leave home without is Ned Suesse’sDoubletake Mirrors. JNS Engineering supplied a heavy-dutyaluminum chain guard and welded-on sidestand footenlarger—a no-brainer feature that should be on everyadventure bike.Motion Pro was their usual big help with miscellaneouscomponents, including their high-end clutch and throttlecables, spring pulling tool, and braided fuel lines with connectors. And, DSA Concepts supplied new white plastics toreplace the original “invisible” dark grey versions.Project Bike 6The stock Suzuki DR650SE webegan this project with.Tip:Use high grade stainlessnuts, bolts and washerswhenever possible. Steelparts rust FAST, and you’llquickly appreciate the extracosts of doing it right.AdventureMotorcycle.com39

Aftermarket Upgrades:ConclusionIf you’re looking for an inexpensive barebones machine that’srugged, built to last, easy to fix, and can handle just about anyterrain the planet can throw at it, look no further than Suzuki’sDR650. The upgrades we’ve shown in this article are ourendorsed options, but if budget is an issue all you’d really needare a set of racks and luggage. However, if your requirementscall for a bike that’s better outfitted, then we recommendexploring what the aftermarket has to offer. The samplingprovided here is the tip of the iceberg of what’s available, butthese products are all tried and true.We’re not quite done with the project bike yet, so stay tunedfor more product reviews in upcoming issues or onthe ADVMoto website. Also note that the bike is slated tobegin its multi-year world trip starting in the fall of 2015.B&B Off Road (BBOffRoad.com.au) 14pannier racksProgrip 714 rally grips 11Vapor instrument panel 99fender brace 30Twisted Throttle (TwistedThrottle.com)choke button 18Denali D2 lights 360 375digital volt meter 50Denali PowerHub2 module 120 329Tuff Lites turn signals (with diode kit) 73Barkbusters VS handlebars 94locking gas cap for Safari tank 33Barkbusters VPS handguardsengine armor 90secondary breather filter 15AdMore LED turning signal strips forBarkbustersTool Tube with locking plug 50DT1 air filter 30Project Bike 7 160 83EPM Performance Imports (EPMPerf.com)Hyperpro 460 monoshockHyperpro progressive fork springs 400Pro Moto Billet (ProMotoBillet.com)CallFastway adventure footpegs & fit kitGarmin (Garmin.com)zümo 350LM 165 67Doubletake Mirrors (DoubletakeMirror.com)rally mirrorsSuperBrace fork braceTrail Tech (TrailTech.net)Black Dog Cycle Works (BlackDogCW.com)throttle control 150 40frame guardsexhaustfootpeg loweringSuperBrace (SuperBrace.com)billet aluminum throttle tube 135rear luggage plateBarrett Products (BarrettExhausts.com.au)Extra special thanks goes out to those who went beyond the callof duty to help make the ADVMoto “Lost for a Reason” DR650project bike possible. Honorable mention goes to: Eric Hougenof Wolfman, Kevin Tanis of Warp 9, Gary Latimer of Vee Rubber,Kevin Nixon of Twisted Throttle, the incomparable Drum Evans ofProCycle, Wayne at Safari Fuel Tanks, Mark Stadnyk of MadstadEngineering, Ron Grace and his wonderful family for their relentless efforts to aid the REZ families of “Lost for a Reason,” and LarryVandiver, Jim “Capt’n” Kirkland, Steve Bortolenedi and FrankieGarcia of Suzuki for their support of this project.ProCycle (ProCycle.us)side plate & mount kitrear rackLook for the ADVMoto “Lost for a Reason” DR650 ProjectBike at events around North America. SuzukiCycles.com,LostforaReason.org 250JNS Engineering (JNSEngineering.com)40W stator upgrade 120 79SW-Motech center stand 170Vee Rubber (VeeRubber.com)tires and inner tubes—VRM 109(knobs); VRM 193 (90/10)and VRM 163 (80/20)CallWarp 9 Racing (Warp9Racing.com)Racetech Electric (RacetechElectric.com) 550 130 300Rox Speed FX (RoxSpeedFX.com)billet wheels (3.5" rear) 900clutch and brake levers 901” bar risers 40sidestand foot* 16Elite pivoting 2" riserschain guard 45Safari Fuel Tanks (SafariTanksUSA.com)reusable oil filter8-gallon gas tank 589rear disc brake guardrally fairing 365lower chain guide 60various engine access coversCallLA Car Wrap (LABanners.com)custom paint job of fairing 550Seat/DSA Concepts (SeatConcepts.com)Madstad Engineering (Madstad.com)custom windshield 97CallMotion Pro (MotionPro.com)spring hook 16T3 Slidelight cablesCallbraided fuel lines and quick disconnectsCall 38 110rebuild seat kit 160Wolfman Luggage (WolfmanLuggage.com)replacement rear fender and bodypanel plastics 255Rocky Mountain saddle bags& accessories 442Shorai (ShoraiPower.com)Expedition dry duffle (large) 139lithium iron batteryEnduro tank bag 95Enduro fender bag 28battery charger 190 85RotopaX and Pawnee plateattachment hardware 249*Special thanks to Steve’s Plating (StevesPlating.com) in Burbank, CA, for welding the JNS Engineering foot onto the sidestand.4040 November/DecemberMarch/April 2015 2014

and Warp 9 joined in as solution providers. Bar risers were provided by Warp 9 and Rox Speed FX to push the stand-ing height limit. And we added Pro Moto Billets Fastway Adventure footpegs (prototyped on our bike), along with ProCycle s footpeg mount lowering kit, to transform the DR into THE most relaxing and controllable bike imaginable

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