DR650 Modifications
Comparing the 6.6 gallon Acerbis fuel tank to the stocker. The Acerbis was intended for an earlier model of DR, so some bike modifications were needed.
Another comparison.
For fuel tank clearance, flip and reverse (left to right, etc) the turn signals.
Step 1, have a friend with a lathe.
Turning custom spacers for the fuel tank.
Custom spacers/pucks for the fuel tank.
Cut down the oil cooler guard for modification.
Another angle of the oil cooler guard.
Test fit before brazing and painting.
A section of tubular steel allows the geometry of the guard to be changed.
Oil cooler guard paint done.
Oil cooler guard paint done.
Seat foam removed, seat pan cut down. The angle of the front of the stock seat pan didn't match the angle of the aftermarket fuel tank.
Measure twice, cut once...and it's still ugly.
Seat foam.
Test fit of new tank and seat, with sheepskin seat pad.
Test fit of new tank and seat, with sheepskin seat pad.
Stock DR650 muffler. Mid-pipe removed to be joined to Ducati muff.
Exhaust sourced from a Ducati M900. Midpipe cut so the stock midpipe can be joined.
Test fit of new seat, tank and muffler.
Test fit of new seat, tank and muffler.
I wanted the bike profile to be as narrow as possible, so luggage wouldn't need to stick out as far. Mission accomplished!
Custom luggage racks, fabricated from 1/2" CroMo steel tubing. Intended to have Ortlieb Rack Packs lashed to them. Additional cross pieces at the bottom are for Rotopax mounting,
Custom side luggage racks.
Custom side luggage racks with loops for lashing down a duffel. Each webbing loop hides a swaged steel cable.
John Scott welding the custom side luggage racks.
Custom brackets for mounting the side luggage racks to the frame.
Final mounting for duffel and rotopax.
Detail of rotopax mounting.
Detail of forward mounting point for side racks.
Detail of rear mounting point for side racks.
Chris helps with mounting an additional storage tube, fabricated from a pellet stove chimney.
To mount a top box to the top rack, I used a bar from a shete metal brake and milled out the diagonal (right) side, to make a U-shaped bracket.
U-shaped brackets attached.
A simple metal tang secures the box in place.
Custom dash with (left to right) headlight on/off switch, 12vdc power outlet, Veypor computer, analog clock.
Custom aluminum side covers. Crafted by John Scott.
Custom aluminum side covers. Crafted by John Scott.
