mods for R65

[bd65gs@gmail.com]

I am riding the length of the Americas and had to do some improvements for the R65GS, so here is a few that may interest some readers.
1.  first the charging system. I was going to use Gerbing heated liner jacket and gloves plus the lights would be on and I was not planning to go fast. the output from the standard alternator is low. the answer was to fit the Euro MotoElectrics Enduralast alternator. this gives 20 amps at 2000rpm. Expensive upgrade but worth it. In addition the diode board is done away with and a remote rectifier/regulator is mounted on the frame. another pus for the upgrade.

2  Carrying a lot of luggage over rough roads will cause the rear sub-frame to crack or brake so a completely new rear sub-frame plus rack was fabricated and additionally panniers and frames made for us by Overland-solutions in Sheerness, England. Ernie has a lot of experience in rally raid prep for bikes and cars.

3  rear shock was indeed a definite replacement. Ohlins are good but mega money so a German made Wilbers shock was purchased and has lived up to expectations.

4  Lights for daylight riding so people see me coming. I found some LED units from china on the Internet and ordered both 9 Watt version and the 27 watt ones. when i tried them the 9 watt was plenty bright enough. So two fitted on the Engine Protection Bars (crash Bars).
Also some extra rear LED lights were fitted as well as a complete LED panel in the standard rear light.

5  of course we gave the bikes few new parts before leave the UK. New Clutch and overhaul the carbs. we had to fit new barrels as a result of them being worn to excess. Apparently Nicasill don't wear out but ours had.  new exhaust valves fitted and timing chain, and new Heidenau K60 tyres front and back.

I'm sure many other thing were done but that's enough for now.

Happy New year everyone
Bob

[nhmaf]

All good ideas, Bob, and also ones that various members here have also done - perhaps with the exception of the new rear sub frame.   I've seen a number of airheads, especially /6 series with the very long seat develop stress/load cracks about 2 inches or so back of the rear shock mounts.  The quick fix was to insert metal rod inside the tubes and weld back together.  It would be interesting to see pictures of your bikes, and the subframe/rack customizations when you can provide them.

Best of luck!  Are you all heading for Ushuaia?
Mike

[tvrla]

Sounds like you work that poor little beast pretty hard! How many miles (Kilometers) on the old cylinders?

What route are you taking through the americas?

[suecanada]

The R65G/S has a 21 inch front wheel right? So an Heidenau can be used. So exactly what size K60 Heidenau's did you mount? I would love to ride with these tires but the 18 inch front and back wheels pose a problem on my LS and it seems hard to get even a rear tire in the smaller 110/xx 18" let alone an 18" front tire in the 90/90 size.  A R65GS sure would be nice to own...I remember when Trolle said a few were being sold by the Danish Army way back.

[Ed Miller]

I remember those, too, Sue.  I figured at the time that shipping would kill me and it probably still would.  Maybe the soon to come Northwest passage will help?

[bd65gs@gmail.com]

Here are a few answers to the questions plus a little more of the changes we made.
yes we are heading for Ushuaia and hope to make it and back to Buenos Aries before the ship leaves that is taking us and the bikes back to the UK on the 29 th. Feb.
Heidenau tyres I purchased were 3.00 X 21 front and 4.00 X 18 rear. the other 2 guys got thees later and fitted 90/90 X 21 and 110/80 X 18. both work fine.
The Cylinders were worn out by the French Gendarmarie, we don't know the mileage covered but it was certainly in sandy and dusty conditions and probably had excessive overheating which I think caused the problem in the Nikasil coating.

We all 3 fitted a new starter motor from Nippon Denso which weighs far less uses less current and spins the motor faster, modern technology is good sometimes.

you can see some of the fabrication done for us at the web site:-
www.overland-solutions.com

I will post photo's on next entry.
thanks
Bob

[nhmaf]

Those NipponDenso starter motors are the bees knees for airhead replacement starters, but they are very pricey.  Still, if I were getting any airhead of mine prepped for such a journey I'd also look to getting one of those - replacements are as near as a toyota dealer, too.