G650 Sertao weight extreme reduction -50kg possible?

timob

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Ok so bear with me here.

I am spending more and more time green laning but I need to travel at least 150+miles before I get to go where I need to and its my only bike which I will be riding all the way to the Pyrenees for this years VINCE. However this bike is just to heavy to do the technical routes I am doing now.

So Options
a) new bike - I would love a Suzuki DRZ400S
b) Make the Sertao lighter

Lighter:
- drop the stock exhaust for a lightweight single can
- lithium ion battery
- cut off the rear subframe and anything I can get off!
- Remove the ABS and the solenoid pump etc looks heavy
- centre stand off

I am sure people have tried this with other bikes. This GS650 is a good bike, the fuel tank is low down, its economical and quite tough. Hoever its at least 50kg too heavy for my needs.

I am feeling the need to get a steel saw and angle grinder out!!!!!

Thoughts? (other than you daft B'stard!)
 
Worthy venture but think you'll struggle.
An easy 2 Kilo saved is to remove the rear pegs (but you've probably done that already).
 
Anyone removed the ABS unit, that has to weight a few kgs? I agree 50kgs seems unlikely but its worth a ponder otherwise the bike is going : (

centre stand -1.7kgs
rear pegs -2kg
exhaust and battery -7kgs

so that's 10.7kg so far.....
 
I've got mine down to about 160kg and that's about as low as you'll get it.

YZ forks, excel wheels, rear subframe, tank, footpegs, footpeg brackets, titanium exhaust, seat, renthal fatbars, alloy top clamp, lithium battery and the list goes on....

C38303C5-ABB6-4489-9C2A-52E96C7A6DF8_zpsuodoh5sl.jpg


Easy mods are the exhaust, battery, bars, centre stand. Then YZ forks and abs delete. Then the tank and rear subframe if you can find them.
 
Thanks Dansin,

That's a great resource. So you managed to get your dry weight down from 177kg to 160kg. How much did that cost you if you don't mind me asking?

Timo
 
If you need a more built for purpose piece of kit, like the DRZ, then personally I'd buy that. You'd have to throw a decent wad at the G650 to reduce it by the 50kg's you want to get too.
 
timob said:
Thanks Dansin,

That's a great resource. So you managed to get your dry weight down from 177kg to 160kg. How much did that cost you if you don't mind me asking?

Timo
Click to expand...

Weight is without fuel so add ten odd kg for that. Toby over on F650.co.uk has a TT Oryx which is very similar in weight.

I've no idea on cost as it's just evolved over the last four years or so. Rear subframe, exhaust, seat and fuel tank etc were about £300 (bargain as the full Pan Racing kit was £3000 originally). Forks plus revalve, springs, service etc were about £500. Wheels were £400 ish. Lithium battery £90. Etc, etc. A small fortune basically. :blast

My advice would be to buy a lighter, more off road orientated bike if you're finding the weight an issue.

If you want to keep the Sertao then do the mods that are easy to reduce lard and sort the suspension which is much more of a handicap than the weight. YZ or WP forks and get the rear shock sorted. I had an mx suspension specialist service and revalve the shock and add compression adjustment to the reservoir. Cost was about £270 for what is now a 3 way adjustable shock.

If you were nearer you could have go on mine. You'd then realise how crap the oem suspension is. :D
 
Hi dansin

I notice your forks don't have a low down 'fork bracket' as the oem version? I did wonder about changing the wheels as I was dropping the rear wheel off to the local shop to put the new tyre on and thinking. Flipping Eck this isn't light! Have you gone for thinner rims on the rear?

I spend all yesterday cleaning it up for sale, even in the flipping snow. Not sure I have warmed up even now.

So if I fit an after market exhaust to it to reduce weight, what type and how much weight. Do you end up with a ludicrously loud bike? (My pet hate)

The DRZ is apparently a noisy bigger even with the oem exhaust, all the after market exhausts make this even worse to the point of being unpleasant. I must admit I am going round in circles with the decision of selling the g650 and getting a DRZ

G650
Pro's

its robust and doesn't need a oil change every 10hrs like a ktm
That engine will keep going for 100k

Cons
It's heavy, it's gets me stuck in mud and I am Losing confidence on it on the tricker technical trails
You can't realistically get more than 10kg off the weight unless you spend some serious dollar

drz400
Pro
its light-er
Everyone raves about them

Con
They don't seem to be made for serious mileage. Lots of rebuilt engines at £15k, loose bolts, cam chain tension needs converting to manual type. Admittedly really easy to fix though.
Really noisy







Sent from my iPad using Tapatalk
 
timob said:
Hi dansin

The DRZ is apparently a noisy bigger even with the oem exhaust, all the after market exhausts make this even worse to the point of being unpleasant. I must admit I am going round in circles with the decision of selling the g650 and getting a DRZ

G650
Pro's

its robust and doesn't need a oil change every 10hrs like a ktm
That engine will keep going for 100k

Cons
It's heavy, it's gets me stuck in mud and I am Losing confidence on it on the tricker technical trails
You can't realistically get more than 10kg off the weight unless you spend some serious dollar

drz400
Pro
its light-er
Everyone raves about them

Con
They don't seem to be made for serious mileage. Lots of rebuilt engines at £15k, loose bolts, cam chain tension needs converting to manual type. Admittedly really easy to fix though.
Really noisy







Sent from my iPad using Tapatalk
Click to expand...

If you go for a DRZ -S as your original post, the standard exhaust should be nice and quiet. The reputation of having a noisy exhaust comes from the standard can fitted to the "E" model, which was more than a little fruity.

I don't think my old drz was any worse for bolts working loose than any other bike i've owner. I never had an issue with the cam chain tensioner, but worth checking the spacer behind the drive sprocket and make sure it's been swopped to a stainless item. The original used to rust and rip the output shaft seal, dumping the engine oil on the road/ rear tyre.

As an alternative, have a look at the G650 XChallenge (a reliable base to improve on, a bit like a drz on steriods), or KTM's 690 (awesome when they are going) if you want to do lots of road work as well as have a giggle on the dirt. Both these bikes are close to the target weight you are looking to achieve with your current G650.


HTH

Nathan
 
timob said:
Hi dansin

I notice your forks don't have a low down 'fork bracket' as the oem version? I did wonder about changing the wheels as I was dropping the rear wheel off to the local shop to put the new tyre on and thinking. Flipping Eck this isn't light! Have you gone for thinner rims on the rear?

I spend all yesterday cleaning it up for sale, even in the flipping snow. Not sure I have warmed up even now.

So if I fit an after market exhaust to it to reduce weight, what type and how much weight. Do you end up with a ludicrously loud bike? (My pet hate)

The DRZ is apparently a noisy bigger even with the oem exhaust, all the after market exhausts make this even worse to the point of being unpleasant. I must admit I am going round in circles with the decision of selling the g650 and getting a DRZ

G650
Pro's

its robust and doesn't need a oil change every 10hrs like a ktm
That engine will keep going for 100k

Cons
It's heavy, it's gets me stuck in mud and I am Losing confidence on it on the tricker technical trails
You can't realistically get more than 10kg off the weight unless you spend some serious dollar

drz400
Pro
its light-er
Everyone raves about them

Con
They don't seem to be made for serious mileage. Lots of rebuilt engines at £15k, loose bolts, cam chain tension needs converting to manual type. Admittedly really easy to fix though.
Really noisy







Sent from my iPad using Tapatalk
Click to expand...

Rear is now a 18 X 2.5 which allows for much better tyre choice.

There's plenty of exhaust options. I've got a set of Remus pipes but they're still twin pipes much less weight than the oem. Scorpion seems popular.

As LTP said, maybe an XChallenge is a better start point, but you'll still need to change it to make it more friendly for road work. It doesn't matter what bike you start with, they're all a compromise!

Getting stuck means you just need more practice and maybe better tyres! A bit more commitment and momentum should see you through..... :D
 
The age old debate...... Cannibalising a serato to save weight... By the time you have done that the negative effect on resale coupled with the cost of replacement parts will make a DRZ a bit cheaper.. I'm a fan of a DRZ but I wouldn't ride it 150 miles green land it and ride home on a regular basis. I'd van it....
Gearing and tires will make the serato easier to ride...
If your a crap rider get a lighter bike, if your ok get better... That's not supposed to be rude either.
 
A little vid for you. It's a steep ascent with lots of loose material covering smooth sandstone. Mav (HP2E) and I got up with one stop. A standard Dakar didn't make it halfway. The XChallenge gets up but the vid doesn't show all of the other assistance. David has it spot on. Get better and you'll be able to get whatever you're riding wherever you want to go.

 
Timob. Appreciate you are in Sheffield, but if you are ever in n Wales you are welcome to try my x challenge for a comparison (though I did sell one of my previous ones to a guy in Sheffield so there is one over there somewhere)

I have previously had a drz e and whilst fine on the trails, long distance road work was an issue.

Last Oct I rode my x challenge down to Portugal, changed tyres and sprockets, and did 3 days on the trails with guys on enduro bikes before doing some more road work before riding back. bike did the trails, and also cruised 70-80 on the roads with luggage.

As Nathan and others said, its always a compromise but the x challenge isn't a bad one.

Dxwalt has one up for sale in the gs section. I don't know it but it looks a good one.
 
CCM 450 is nice and light, good range and wonderful suspension. Ridden it down to Toulouse in June, off to Spain for the Vince's Mini mondo. It's a D road bike rather than an autoroute blaster, but doesn't need a Van. Not cheap, but can be found SH. 140-145 KGs fully fuelled.


Sent from my iPad using Tapatalk
 
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