Category Archives: Project Bikes

What I’ve ridden and what I’m riding

Motorcycle Luggage Racks

Originally written 2012, overhauled 2020
There are 24 pages on luggage and racks in AMH8
See also MYO racks on this sticky HUBB thread

The problem with off the shelf pannier racks like the classic ‘racktangle’, above left and right, is that they:

• may not make them for your bike
• may cost more than you’d like
• are too wide
• are often too far back

Those are some of the reasons I made my own rack for my first travel bike, an XT 500 (below), way back in 1982. It was rubbish but it did the job.

On the next couple of trips I used no rack. People do manage – usually on smaller bikes with lighter loads – but for overland travel, classic, strap-over throwovers are a throwback to a twin-shock era. The problem is usually with the high pipe of a trail bike. The bag presses on the panel which melts and – on a hot day on the south side of the Sahara (below) – the plastic catches fire soon followed by the ex-army canvas panniers and your favourite pyjamas.

Small baggage fire near Arlit, Niger.

What is wanted is a rear rack that attaches to the subframe and other key points as low, forward and close to the bike as possible so the mass follows suit, while allowing for those instinctive corrective dabs when losing control, as well as paddling in soft terrain.

I first saw a ventura rack in the early 1990s on the Tanami Track in northern Australia (left) and was so staggered that dirt touring bikes (admittedly, possibly two-up?) could be loaded like this that that I put a picture in the first AMHandbook and nearly every edition since. Ventura’s idea is that you can reverse the upright bar to point forward to load your sack forward to improve ‘weight distribution’. Tell me about it.

In a nutshell the mass wants to be as close to the bike’s supposed centre of gravity as possible which, with a load and rider aboard, is in the region of the injectors (right).
‘Mass centralisation’ became a buzz word with Honda bike design a few years ago, and was a concept applied by bike makers like Buell. 

It makes sense, especially on a loaded motorcycle traversing less than perfect roads. The more central the mass the more predictably the overland-loaded machine responds to the forces of its own inertia as the suspension moves the sprung weight up and down over rough terrain. That adds up to better control, no freaky handling vagaries like tank-slappers, smoother riding and so less fatigue. All up, the key to surviving a long day on the road in the AM Zone.
Above left: mass decentralisation. Think of the leverage!

Platform racks

As mentioned, when it came to making a rack for my XT500, the idea was fairly obvious: make platforms (left).
Even though I’d been despatching for a few years with throwovers or more commonly just a big top box, when it came to carrying a big load to the desert, a low platform down on the sides made intuitive sense.

The execution using Dexion shelving was poor, although that slack-rack did carry the load to the desert and back – albeit with a radically reduced once I came to my senses. It probably survived because there was so much jelly-like flex it was unable to summon up the tension to snap outright. The mld steel ‘L’ platform element was bolted onto a Craven rack – the ‘Jesse Luggage’ of its day, with plywood planks screwed on and sharp corners trimmed

Platform racks have been around for years, among other places used on army BSAs in the 50s and 60s (left). I’ve always liked the principle but these tinny, hinged trays were designed to take a specific panniers or to swivel up out of the way when not in use. It’s a logical and effective form of support. Within limits you can securely load anything on there; box, bag, sickly calf, bulging sack, except the sliding support arms get in the way of bigger loads.

Same goes for the solid (unhinging) version, left (notice the nifty mini inner platforms too). A secure placement for alloy boxes which would need next to nothing to stay in place.
I had similar racks made for the Sahara, but using soft bags (below), but you can’t help worrying about that hard front edge on your lower legs. This never occurred to me until Desert Riders when we added big metal boxes to remind us how they might hurt.

When using a rigid container like an alloy box there’s no need to have a full-width shelf; an inch-wide ledge will support a metal box, as it did on our Desert Riders XRL racks (below). The welding was superb but that rack was over-built, slapping metal over metal in search of strength but actually blinding the function by adding excessive weight. We did carry very heavy loads at times (left), but two of the XRLs cracked their subframes.

The reason platforms are not used these days is that sticking out looks inelegant, injury inducing and damage-prone in a fall. But when overlanding, your gear is on there all the time and so a fixed platform rack is no different from the angular edge of an ally box, except when it comes to removing baggage and wheeling a bike indoors overnight.
Below, Sean F’s very neat fixed platform rack addressing some of the issues for his soft-bagged DR650. if you get platform racks, this would be an idea to copy.

I still like the idea a platform rack with a hinged element so as to carry anything that fits while being slim when unloaded. The problem is without using the BSA sliding struts requires some sort of unsupported platform or cantilever. As always, you need to visualise how it will respond to slides down the road or hours of corrugations with maximum loads

There are various ways of arranging this cantilever, but the only one I’ve seen was on these Chinese 125s (left) pictured in Angola. If you look closely you’ll see the pivoting platform swings out to rest on a shallow ‘L’ bar. Providing it’s chunky enough, the leverage on the pivot and load on the bar ought to be met. A wider ‘L’ rest bar means less stress but you don’t want the fixed part being too wide.

A search on Google Images most probably identified that ‘Angolan’ rack (right) as one produced by none other than The Chongqing Meihuan Machine Manufacturing Company.
With a closer look you can see the pivot/support works by lowering on a spring to rest horizontally on the pillion footplate. Note the sub-racklets at the back, too.

And here is another hinged plat-rack made for this lightweight utility bike by former Italian custom bike maker, Borile. Like the Angolan rack, it’s a bit on the wide side for overlanding duties rather than transporting your goods to market, but the principle is the same.

There loads more on racks and baggage in the book.

GS500R Overlander – First Ride

Index page

A little more than three years after I bought it, my GS-R got wheeled out of a Derbyshire hilltop hangar to prepare for it’s maiden flight – a run of a few hundred miles to far northern Scotland where development is set to continue.

Since my last brief ride round the lanes, the suspension got lowered a bit, the stands trimmed to fit and the pipe levelled off to make room for a rack and low/forward luggage, when that day comes.

P1060310

As I pulled on my clobber Matt and Andy wired in a cig socket (left) to run a satnav, and with that done I set off into the rain to see how far I’d get that night.

There were small problems of course. The only way to securely load my gear was to pile most of it on the back – some 20kg right off the back; anathema to good loading and balanced handling. The GS is especially bad as it has a short back; I sit only just in front of the back axle. If I took my hands off the bars they flapped like a flag in the breeze. Then there was the limp back brake. As mentioned, I suspect it’s down to a too large GS master cylinder working the DR650 calliper so the ‘hydraulic advantage’ is cocked up (well explained here). Even extreme pedal pressure won’t lock the wheel. And besides that, the bike was long unused and untested – the new front end, wheels, the chain run and so on. With a lot of scope for something to go wrong, I initially kept off the motorways to simplify a recovery or roadside repair.

P1060338

I splashed my way through the grim industrial conurbations between Sheffield and Leeds and spent the night at a mate’s in Shipley, trying to revive my Garmin Nuvi which either got wet or died of its own accord. Next day promised to be brighter before the next apocalyptic weather event (due to the displaced jet stream) bore down onto the UK. So I set off early to cross the Pennines I knew well as a walker, scooting up the A65 across the Yorkshire Dales before taking the A683 moorland backroad (left) to Kirkby Stephen for a snack in the Market Square (right). I knew this bench well too, having last sat on it at the end of a long day’s walk from Shap on the Coast to Coast path. The sun was out, but that was to be the last I’d see of it for another 10 hours.

I followed the A66 onto the M6 where the Suzuki held its own, stable enough up to around 80. I’d heard Halfords were doing specials on satnavs, but in the Carlisle branch there were no worthwhile deals. However, filling up gave here me a nice surprise: 176 miles on just 11.1 litres. That’s 25.35 kpl or 71.5 mpg (nearly 60US) – as good as the modern efi BMW I rode last March at about the same speeds. Not bad at all. With the GS’s 20-litre tank that’s 500 clicks or 300 miles to a tank. The rest of the ride got occasionally faster and fuel economy dipped by around 10%.

The weather was supposed to improve as I got further north but they got that wrong, and then I made a right mess of getting across Glasgow. I should have gone under and up the left side for Dumbarton and Loch Lomond, but with only the compass on the Voyager and not enough signs, I ploughed on northward and after an interlude in some suburbs, went back in and up on the A81 signed to Loch Lomond – but the wrong side.

Still, there was more daylight than I had energy to keep riding, so I stayed on the A81 over Dukes Pass (left). ‘It’s  a bikers’ road’ said the green-haired girl at the servo in Aberfoyle – but not in the rain with a balcony hanging off the back of your GS5. Like everywhere else, she had no map for me but said turn left at Callander, by which time I was back on roads I knew; the way to Glencoe and the Highlands.

Five pm. Nine hours on the road, I should have been starving and wilting, but was feeling OK. Fish and chips is one of the most over-rated Brit dishes, but I tell you what, a haddock supper at the Real Food Cafe in Tyndrum with their home-made tartare sauce might be a bit skimpy and pricey, but was just about the best I’ve ever eaten.

From here it was about another 200 miles – probably four hours with another fuel and snack break. Up over lonely Rannoch Moor, a tempting nod towards the cosy Kingshouse Hotel and down through the famous valley of Glencoe (right). In and out of Fort William – Scotland’s ugly but functional outdoor adventure capital, and then a route I’d not done for 30 years, up the side of Loch Ness.

rodney

By now roads were drying out and the ill-balanced GS and I had melded into one amorphous lump. You know that feeling at the end of a long day’s immersion on a bike; you’re shagged out but riding intuitively while the bike itself is warmed through and on song. But you’re not a machine and eventually you’ll get too tired to concentrate, so I pulled into a village servo for a chocolate injection and took a quick sit on a German bloke’s knee-high Harley Night Rod (top left) with a back tyre three times wider than mine.
On my near empty stomach the Star Bar the trick. I perked up and rode away from the uninspiring east coast farmland, west over the moors and down to the Hebridean shore. A moment’s rest on Ullapool waterfront to wipe the bug-splattered visor against the setting sun, followed by another hour’s ride into the mountains of Assynt and touchdown.

gmap

Five hundred and fifty miles or nearly 900km in 14 hours, with about 12 hours of actual riding rarely over 60mph. Nineteen hours of daylight helps of course, but this wasn’t like crossing the Montana prairie. I’ve not ridden anywhere near that far in the UK before, but was surprised to arrive with no single source of discomfort, be it back, butt, neck or knees.
That suggests that the GS is pretty comfortable overall, even tensed up riding an unfamiliar bike in wet weather. As on any bike, the over high footrests can be dealt with by stretching the legs forward once in a while, and I plan to fit some flat track bars off an American Bonnie. The screen needs to grow to a useful height, too but must have had some positive effect. And when I think how I suffered on that BMW in March, you got to give full marks to the Suzuki seat.

The DR front end brakes fine too; it’ll be great to have the back doing the same. Most of all I feel the 19-inch front wheel was worthwhile. On a 21-incher the wet bends and higher speeds would have been a little more edgy. As for the skinny back tyre, no moments there (a pretty worn Metz Tourance 110/80 radial marked ‘front’, plus a Chen Shin Hi-Max 110/90 on the actual front). I wonder if that back radial at 36 psi helped the mpg? Either way, I look forward to having the GS shod with new Heidi K60s on Tubliss.

Didn’t have a chance to test the headlight – it’s never fully dark up here at the moment – but I’m sure it’s terrible. And that light is on all the time, even when electric starting which seems dumb. A switch is needed. The indicators and back light are aftermarket LEDs, but some sort of HID will be in order to help light the path. A mate’s recommended the VisionX Solstice for nearly £100.

According to the Trail Tech Voyager’s wheel-sensor based data, the GS’s cable speedo reads 12% over with the 19-inch front wheel on a [21″] DR hub, but the odometre is only 2% over. The Trail Tech packed up towards the end of the ride – it wasn’t charging off the bike (loose at the battery, easily fixed) but while it worked I loved it. Engine temp, air temp, compass, speed and odo – all things I like to know. And it’s has a map page too, though aimed at short range trail riding it can only handle small maps. Looking forward to delving more into this gadget.

At 30-something hp, the GS doesn’t exactly crease tarmac on steep climbs. And it needs to be spun at over 4000 to respond. At 5300 it’s indicting 70 – a true 63mph. I rarely rev it higher through the gears, but that’s still only halfway to the rather far-fetched redline of 11,000 rpm. Compared to other things I’ve ridden there’s not much torque low down in this thing, so I suspect the GS-R would be unresponsive on the dirt. It’s still on the tall side and heavy for that too, plus the pegs as so high the bars would be at knee level when standing, but the suspension isn’t flabby or harsh, and there’s more than enough of it. I do wonder about the strength of the frame for overland travel. I know it’s only a cheap a Suzuki, but it doesn’t look especially robust close up. All the more reason then to keep the load light and low.

What’s it all cost me? The bike was £1500 (five years old and 11,000 miles at the time). The Talon wheels built onto DR hubs were £400. Back shock £40, DR front end £200 by the time I bought a spindle and speedo drive. Other bits £200. I got back a few hundred quid selling the original GS500 front end, wheels, shock and other bits which paid for the labour, so we’re looking at around £2500. Add the new tyres and Tubliss cores for £250 and whatever it will cost to fabricate a rack. Spread over the years that’s not had too much of an impact, and the great thing with the GS5 (less so the DR650) is that parts are dirt cheap. There are chassis on ebay now from £30. Once completed it ought not cost much to run the GS-R.

GS500R Overlander – progress report

GS500R Index page

The GS500R Overlander project bike is taking shape, although it’s not quite a fully set jelly. The critical mod: adapting the rear DR650 hub and brake to fit the donor bike’s swing arm and chain run has been completed pretty seamlessly by Matt and his team of farmyard engineers (see pic below).

I know what you’re thinking: why does the front tyre look fatter than the back – is it the camera angle? No, it’s just that at the time I didn’t want to waste money on new 19-inch tyres in case the GS turned into what the French would call, un piège de mort. So I bought used cheapies just to get the thing rolling, first for the front, and a while later another for the back which was not identical. Just as well really, as following my recent Morocco trip I’ve discovered that Heidenau K60s are the ‘bomb’, as the bloke on the right would say.

Half-built impressions of half-baked bike
It took a bit of firing up off Matt’s V8 Landrover offroader to get the GS running while whipping out a plug to dry and blowtorch. Even then the GS didn’t seem to run well. Was there a badger nest in the air filter? I could barely pull up the track to the road, and while slipping the clutch mistakenly thought it was because the gearing was way off. As with most things on this build, we took an educated guess here, but at 42/16 the gearing’s actually turned out to be in or around the ball park.

Running down to the village to top up on fuel I thought, jeez, this 500 really is a lot slower than the BMW FGS650 twin I’ve been riding lately. Of course that bike has got at least twice the horsepower and 20 years of development on the G. Heading back, the weight of that extra tenner of unleaded in the tank saw the bike struggle to escape the dale. Something was not right. I pulled over and pulled off the left plug cap – no difference. A ha! as the bloke on the right would say. A little bit of fiddling with the plug cap got past more cobwebs, the second barrel fired up like a Saturn V and suddenly the GS500 was running like… a GS500.

I tore off up the lane like a teenager on his first moped, awestruck at the feeling of raw power. Like Ogri’s beaky-nosed mate Malcolm (left) I was heading for a prang, so it was time to consider braking. The DR650 front end’s disc had been binding a bit as the pads off one scrapped DR got to know the disc rotor from another. A quick check at the fill up proved that the rotor wasn’t getting hot and causing the lame performance. In fact, yanking the lever did see the forks dip hard in response so it can get there if it has to. I guess it’s just not the quality of braking I’d got used to while running the 2012 BMW. The back brake was considerably slacker, partly we suspect because the DR650 calliper which had to be used to clear the Talon spokes, may not compliment the bore of the GS’s master cylinder. So the back brake is mushy and with a long throw. Maybe a bleed or a braided hose will bring it round, or a master cylinder off a DR.

Another problem. The main stand had to be extended by several inches (right) and it now takes an extreme heave to get the bike up; not something I could see myself being able to do with baggage at the and of a tough day on the road. The feet are now clearly too far back from the pivot point for the factory-set leverage. And yet it’s as long as it needs to be, lifting the back a couple of inches off the deck, like a normal stand. Curved stand feet could get round this.

But in fact when I think about it, the GS is a bit too high; I can’t get my feet flat on the ground. With the new suspension and the 19s it’s probably jumped up at least four inches judging by at the extended stand. I really appreciated the BMs low height on the dirt in Morocco and am not looking for masses of clearance on the GS-R. In fact this will be easy to modify: slide the forks up the clamps and back the shock off max preload where it is set now (left). Didn’t get a chance to do all that, as it was a flying visit to the Mattlabs.

Steering feels a bit slow too, but I think the height may have something to do with that. As it is I don’t think the steering of a regular GS500 would get a job in a bread slicing factory. Getting used to the bike and modulating suspension levels may fix all that, and anyway there are new tyres to come. The dirt bars too felt a bit narrow for my liking, or no wider than stock and maybe could do with a lift. Again, easily done.
It’s hard to tell if a thinner back tyre greatly affected the steering or ride, not having ridden a bike with back-to-front tyres before. My plan is to run identical-sized tyres front and back. One thing’s for sure, the seat feels great, although as mentioned earlier, the rear-set pegs could stitch the knees up on a long day – and that could be crippling. So maybe some sort of highway peg off the crash bars will work.
One good thing, even though it’s tall right now the GS feels pretty light for what it is and a good 20 kilos lighter than the BMW GS650 which was at least 200kg. Might try and weigh it one time.

What’s left to do
Once the above mods are seen to Matt the Mig or Andy the Arc are going to fabricate a rack, but not just another off-the-shelf, too-far-back, 18-mil loop jobbie like I used on Morocco on the BMW. Something as securely mounted, but with a hinged or somehow retractable platform plus a ‘sheep rack’ platform on the back – always handy. That way the pans can sit rather than hang – a much better arrangement for an overland load, IMHO.

I was going to fab’ some PVC pannier liners with a heat gun and roller, and a mate had offered to sew me up some Cordura outers. I would have kept the Monsoons I used in Morocco if only they had been my ‘Fibonnacci shape’: less wide, more long and bigger, but since writing this Adventure Spec have started selling a ‘Magadan bag‘ with input from Walter Colebatch and based on the Steel Pony Gascoyne he’s used in Russia and a bag whose dimensions I’ve admired myself, if not the canvas fabric. If all the hard work’s been I’m be happy to order me a pair.

One thing I was also thinking of is junking the fat OE pipe and fitting something like this (right). A cheap ‘one-size-fits-all’ mega can be bought of ebay for 30 quid but I’m not 17 anymore and couldn’t bear a loud pipe or unravelling all the jetting and valve-burning issues. It seems the GS muffler only weighs some 5 kilos anyway so if pannier space is so important why not just chop the regular pipe at the neck and drop the angle as in the gif below. It’ll be good to have the bags in close and the pipe underneath, and its an easy job, giving what, at least four inches more bag space. After my over-width Morocco experience and seeing how slim the GS is, it would be nice to keep it that way.

Anyway, I’m off to the Overland Expo in Arizona in a couple of weeks, a great chance to pick up some goodies in the US, including a pair of Tubliss liners (left) which enable you to run tyres tubelessly on spoked rims. As you may know, I tried doing that before without complete success.

I know Tubliss are said to be for off-road use only, but I’ve interpreted this to be an issue of legal liability on the pubic highway rather than anything to do function or real-world safety. Robin, with whom I rode in Morocco last month has run Tubliss on his TT250R all over the world for years (that’s him right with all his kit – including full camping gear).

A meekly powered GS500 with a modest payload isn’t going to tie the tyres in knots. I plan to fit the front 110/80B (59 T) K60 Scout (my review) I used on the BM in Morocco (left) and another new one for the back. The 100/90 57 H is a tempting 30% cheaper and still with a load index 230 kilos and a 130mph rating, neither of which the GS will see in its lifetime, but I’d need two so I’ll stick with the wider 110/80 at another 100 quid.

More news as it happens.

BMW F650GS 4000-mile review

Released in the UK in February 2012, the ‘SE’ suffix in BMW’s F650GS added up to a new paint job and an array of optional Special Equipment.
As a reminder, the ‘650’ uses the same 795cc engine as the more popular F800GS, but detuned to be more tracable and more economical, with higher, road-oriented gearing, shorter suspension travel, a lower seat, cast wheels with a single front disc and tubeless tyres.

The bike was loaned by BMW Motorrad and I rode it from new for over 4000 miles from London across Spain to Morocco and back in March 2012 to update my Morocco Overland book. I set off with around 600 miles on the clock, just after the first service and was out for three weeks.

My bike came with a batch of these optional extras: main stand, trip computer, heated grips and ABS, all of which I learned to appreciate. At the first service it was additionally accessorised and modified as follows:

  • Heidenau K60 tyres
  • Metal Mule rack, tall screen and rad guard
  • BMW bash plate, engine protection bars and hand guards
  • Touratech sidestand foot
  • 1 tooth smaller 16T front sprocket
  • 12v plug
  • Ram mount
  • Aerostich wool seat pad

Why the ‘650’, anyway?
Now they’ve had their teething problems sorted, I believe the ’650′ is the best of the two F-GSs twins for real-world overlanding. I wrote as much in the AMH6, even before I rode the bike.
BMW Motorrad did suggest I might like a new Sertao for the Morocco job, but that bike overweight slug has little to prove. Overall, I prefer the unsnatchiness of a twin over a big single, and there’s apparently less than 10 kilos weight difference, while you get a more smooth power and nearly-as-good economy. With damage protection, moderate speeds and alternative tyres, the 650 twin was fine on dirt roads and, with the exception of gearing, everything that differentiates the 650 from the 800GS makes it more suited to overlanding.

Comfort
On collection, the BMW felt comfy and natural to sit on, but I was warned by another 800 rider that the seat would be uncomfortable. Though I’m sure one man’s sofa is another man’s slab of coarse granite, for me at well over 100kg in all my riding clobber, the seat was the bike’s biggest flaw, just as I’d speculated while running in. Sadly, the Aerostich wool pad made little difference.
I put in a 600-km run across Spain on the way out from which my butt probably never recovered. That was followed by mostly sitting down on the pistes to spare the bike and baggage too much of a hammering (and standing was a bit awkward without bar risers), all of which probably helped beat the seat’s foam into powder.

By the time I turned back from southern Morocco, soreness returned so soon that when coming over the High Atlas, I couldn’t face the 1500 mile ride home. I pulled up at a village mattress shop and bought a 50mm slab of foam (left) which tucked in easily under the Aero pad (below). The soreness passed in a few days and Spain was crossed in an 800-km stage without agony. I recall the same discomfort on a GS1100 I borrowed years ago (confirmed by an 1100 rider I met on the Bilbao ferry) and even a GS1200A rider we met in Morocco said his seat was not up to the bike, and he was a light guy.
What is wrong with this seat – surely it’s something they’ve got to the bottom of (boom-boom) over the years? I suppose function may have suffered in the face of slim design to complement the bike’s looks, just as a Triumph Rocket III has a huge saddle to emphasise its bulk. It’s not all about width though, it must be foam quality or density. The Tenere’s saddle was no wider as I recall and was even hampered by a lip which stopped you moving back, but it was nowhere near as painful to sit on after two hours. There’s a bit of buried chat here on UKGSers about F-twin seats. It seems the inflatable Airhawk pad is the simplest solution if you ride long hours.

Even though I’m 6′ 1”, the low seat height was just right, if a bit low for easy standing up. It meant dabbing and paddling in sand or steadying over rocks was easy, but didn’t make the bike vulnerably low; the bashplate very rarely bottomed out, though caught plenty of flying hits.
The OE high option screen was way too short for me and without the taller Metal Mule item (left) the ride would have been grim, as I realised when I returned the bike without the screen and felt my arms lengthen by an inch. But as mentioned, I feel the top edge of the MM screen curves back too much and anyway, it’s still a little too low for me. Although it caused no buffeting, any clouds of bugs got splatted straight onto my visor rather than blown over like they’re supposed to. A couple of inches longer and it would have been perfect.
I never felt the screen was a distraction on the piste, though if I’d gone over the bars I’d have ripped it off for sure. For me, the Tenere’s screen – more upright and further forward like a Dakar racer worked better once I clipped on the clunky Touratech extension (it was too heavy to fit on the MM screen). But as with seats, finding or adjusting a screen to suit your exact prefs can take a while. One size does not fit all.
It may be lower spec’ and shorter than the 800 model, but the firm suspension suited me fine, giving predictable behaviour in bumpy bends with no wallowing – better that than too soft, although taking the bike back the thought ‘harsh’ cropped up again. The only time I meddled with it was a rocky day’s riding without baggage when I wound the back out with the handy pre-load adjusting knob and lowered the tyres a bit more to soften the ride.
While you do feel the engine vibration at higher revs, it never intruded on comfort, nor did engine noise which either sounded great at town speeds, or was drowned by the helmet din. The light clutch was a real pleasure to use too, and got plenty of use at low speeds, feathering in first to get round the still-tall gearing. Despite that it never needed adjusting, neither did the foot controls. Some days my right knuckles got very sore from the holding the throttle open while keeping two fingers over the brake lever, but other days they didn’t, so it must be me.

Economy
The BMW comes with a 16-litre underseat tank. I was expecting excellent economy and most of the time I got it, though the average of 68.2mpg / 56.8US / 24.16 kpl / 4.14/100km over 23 fill ups was about 4% less good than the XT660Z’s 72mpg or 25 kpl. Of course, you get a smoother and more powerful engine. Worst result was a 51mpg on a partly sandy piste where I stuck with street pressure tyres for too long and so wasted a lot on wheelspin while pushing and paddling. Best was an 80mpg (28.3kpl) coming off the Middle Atlas, with quite a few 70mpgs when riding at <60mph with my mate on a Yamaha TTR250, much of which included piste stages with hours in first or second gear.
I don’t believe the wide baggage, tyres, high screen, heated equipment or the slightly lowered gearing had any real effect on fuel consumption, and like the Tenere, it seemed to be getting better and better as the miles wore on. Full records, here.

There was some pinking in deep sand, partly due to the hot conditions, tall gearing and the 12:1 compression ratio. With the fan whirring and the throttle virtually closed in 1st or 2nd, the fuelling would start surging, but it was never uncontrollable, just mildly annoying, although it did seem to coincide with higher fuel consumption figures.

Oil, water, drive chain
In 4000 miles no oil was used and I didn’t even think to check the water. I adjusted the chain once and even that may have been premature, which means BMW may have gone OTT to fit a quality chain after the early breakage issues. I oiled the chain most days with engine oil, but on reflection, this did little long-term good as it was soon thrown off. Next time I’d brush on thicker Tutoro oil.

Performance
The 650 has all the power I need and in fact I’d have liked to have tried it in the detuned 34hp version, assuming there are notable benefits in fuel consumption or cool running. I never needed to rev over 4000 while accelerating, and with the lower gearing, 5000rpm at 80mph was as fast as I went. The red line is at 8500.
The low rpm power really helped on the piste, pulling out of deep sand, even if the high, road gearing was not ideal here. Like I say, I’d spend all day in first or second.
Fuelling was smooth and very responsive, although this made the bike a bit of a handful the one time we rode a day on the piste with no baggage to damp the response. As mentioned it would start surging when it got hot – a slow track with a backwind – but that never lasted more than a few minutes until a higher speed cooled it down. Running at very low rpm with high gearing meant slow oil and water circulation speeds may not have aided cooling as much as they could.
With just a single disc on the front, the brakes were well matched to the bike’s performance. At least once the ABS stopped me from skidding over the edge while checking out the scenery, though I’m told the mass of brake fluid pumping around for ABS can contribute to the slightly woolly feeling at the lever. I never thought to turn the ABS off on the piste, and can’t imagine it would be necessary at the speeds I rode, as it came on reassuringly late on the dirt.
And as for the twin bulb front headlight, that was pretty good too on the few occasions I rode a night.

Road riding
On the road in Morocco I rarely exceed 60mph. At this speed riding is less tiring, safer, the cops won’t nail you and economy stays good. I felt the bike was stable up to 70mph on the K60s though at times there was a very slight wobbling from the headstock (as opposed to a weave), and possibly only on concrete highway surfaces in Spain. With the upright seating position, wide luggage, trial tyres and tall screen, I can’t say this bike felt that surefooted at high speed on the way out, though by the way back I was able to sit up to 80 with more confidence, either because the Heidenau tyres had worn in or I was more in tune with the bike’s movements. I also think saddle comfort makes a bike handle better; when you’re tensed up in pain, your rigidity can affect a bike’s response. I met a GS1200 Adv rider who’d ridden both models and said getting back on his big 12, it just sat on the road like a wet pizza, however, you loaded it, largely down to its mass and the telefork.
Loaded up, the F-GS was hard to turn on hairpins, both on or off-road, just like the Tenere it tended to run wide or understeer. The Tenere was a tall bike but on the BM I attributed this to the seemingly long, 1575mm (62 inch) wheelbase. The bags were slung as far forward as possible. Early on I noticed the bike’s balance at sub-walking pace was very good; you can easily keep your feet up at 1mph and this must have helped with low-speed control on the piste.
To be fair, some of the roads and tracks in Morocco are very narrow and tight, with the wide baggage pushing you out towards thought-provoking drops. Even some mountain back roads have strips of gravel down the middle from uncleared landslides where any big, loaded bike would struggle to progress quickly and smoothly. One time I found a well-surfaced road tar in the Middle Atlas and blasted along from bend to bend around 60 or 70, but you can’t forget this is a relatively tall bike for that sort of spirited riding.

Off road riding
Dirt biking in Morocco is mostly on rocky or gravel tracks, and much to my relief the K60 tyres were uncannily good. I’m sure the OE Tourances or whatever they were, would have been less effective.

I take it fairly easy when riding alone on the piste, for safety and to spare the hammering on what is really a road bike. Within these limits I was amazed to find how easy the bike was to handle with its low seat, light clutch, ABS, firm suspension great tyres and good clearance – and all despite the tall gearing, occasional hot surging and tight turning limitations.

Early on it was quite disorienting how well the bike would track straight in deep sandy ruts, right up to the point where I lost my nerve, or less often, when the front tucked in. When this happened the instinct was to lean with it while standing up and gas it, all in one swift movement, to which the bike responded correctly every time, surging forward to regain its steering composure. The full-length bash plate meant you could do this confidently on any rideable surface and take the hits. Though I had my share of these moments, I never fell off the GS or got so wildly out of shape that I thought I might do.
Not surprisingly I found the handlebars were too low when standing up off-road, causing me to crouch unsustainably. Most bikes are like this at my height, though handlebar risers would have easily fixed it; something I forgot to address before I left.
Of course dry dirt and even sand are fairly easy to ride on any bike with clearance and the right technique and tyre pressures. I’m sure the K60s would have clogged up and the weight got to me on very muddy tracks, but all in all, I was pleasantly amazed how well the GS coped off-road in Morocco.

OE and extra equipment
The dashboard was slightly harder to read compared to the higher rally-style layout on the Tenere. Speedo numbers were a bit small, and the computer lacking in contrast and clarity in sub-optimal conditions.
The computer is pretty good though, and besides the total mileage, two trip metres, clock, fuel and water temperature levels and nice big gear indicator, a button on the left bar lets you toggle between air temperature, average speed or mpg (both resettable though I couldn’t work our how) and live mpg which could dip down to the high 40s uphill at 70mph, or give a maxed-out figure of 199mpg cruising downhill on a shut throttle. Interestingly, it must be all pretty accurate as the computer’s average mpg of 68 matched my own figure which was calculated from actual volume and distance at each fill up.
I’d have preferred a digital speedo that can switch to kph like the Tenere, while the indicators and other switchgear I eventually got used to, though in a panic, might well get it wrong.
The temperature gauge never budged, but the fan came on quite a lot. I do wonder if the close-fitting Metal Mule radiator guard may have exacerbated this. I’d be tempted to mount it an inch forward to get some more circulation behind it without losing protection. I’ve heard the fans or fan switch packs up on F-GSs when they get clogged with grass or mud – but that’s not unique to this model
The fuel goes to reserve at round 12 litres, or between 180 and 222 miles. The furthest I ran the tank was 238 miles at which point it took 14.3 litres. There are 16 useable litres says the handbook, but the capacity is 18 – I’m never sure which is which.
Checked against a GPS over 34 miles, I found the odometre (distance recorder) to be a mile over so about 3% out, though I’m not convinced GPS distance recordings are always that accurate as it depends on the set-up in recording frequency. This means that my mpg readings are a tad optimistic assuming all fuel bowsers were correctly calibrated; on some fill-ups in Morocco I did wonder. As for the speedo, at an indicated 60 or 70 it’s 5% out according to GPS, so the bike reads a little faster than it is.
Non-OE equipment besides what’s been mentioned all did the job, the BMW bashplate took a lot of flying clunks and clangs on the chin but rarely landed hard, their engine bars were only used as pouch racks I’m pleased to say, same with the lever guards, though the handguards could have been much bigger against driving rain, like the Acerbis Rally buckets of old. The Metal Mule rack was never taxed, helping merely to keep 20kg of throw-overs off the bodywork, and as said, the Aerostich wool pad couldn’t disguise a seat fit for the welcome centre at Guantanamo Bay.
As always my nifty tank net, this time used with a foam pad to protect the paintwork, was a great idea, and the Touratech GPS holder on a RAM mount held up (the Nuvi satnav I laid on the tank foam when off-road). The Garmin 12v cig plug leads both on the 76csx and the Nuvi began playing up. Hardwiring as we know is the answer to that one. My engine side pouches were dead nifty for handy access to water, oils or stuff in general, even if they are more Steptoe & Son than Rally Pro.

Durability
Not a single thing malfunctioned, broke, came loose or fell off and so I feel the BMW has been very well screwed together.

Summary
The Morocco run confirmed my early impressions while revealing how well the GS coped with dry dirt tracks. I feel the same way about what I liked and disliked at 500 miles but have proved that this ‘650’ doesn’t just look like an adventure touring bike; with appropriate tyres it performs like one too. Once that seat is fixed (there must be several solutions out by now) the 650 GS ought to offer continent-crossing comfort with adequate fully loaded off-road ability. With the smooth and tracable twin-cylinder engine and nearly as good economy, I’d say it makes a great all-rounder.
The only truly unresolvable fly in the off-roading ointment was the tall gearing. Dropping a tooth on the front sprocket didn’t really fix that, fitting a couple of teeth more on the back would – but the clutch didn’t complain. Now the 650GS SE looks less drab, that’s the only thing I can see that works better on the more powerful 800 model.

Since I wrote this the newer ‘700’ model (left and below) has come out alongside the new 800. With revised styling, a bit more power, a second front disc but barely modified gearing. It’s also sai the 650 runs better on low octane fuel which is a big plus in the AMZ. More 650 vs 700 here.

A few years later I rode a well-used, rental 700 for a week and liked it as much as the 650. And a year after that tried the new F750GS too.

Honda XR650L – 4000 mile report

XRL Choice • XRL Preparation • Desert Riders

Despite early reservations in Tunisia (it’s always the way on your first ride fully loaded), we agreed the bikes made a good alternative to a KTM 640 Adventure which was our second choice.

What we liked

  • Descent suspension (but see below)
  • Economy (but Andy’s was mysteriously 15% down on ours)
  • Clutch and gearbox took the hammering well
  • Engine never baulked at crap fuel
  • Despite low bhp, it was never lacking
  • Very accurate speedo/odo
  • Anvil-like reliability – worth a lot out in the desert

What we didn’t like

  • Too high and top-heavy with that giant tank (oh really?)
  • ‘Sternwheeler’ steering (due to oversprung front end)
  • Rough riding with alloy panniers – smaller and soft next time
  • Accurately measuring the oil level
  • Skinny rear subframe
  • Accessibility for rear spring adjustment

Worthwhile mods/gear

  • Tough tank and rack fabrication
  • Nifty Petzl Zipka head torches
  • Michelin Desert/T63 knobblies
  • DID gold-plate chains
  • Foam Unifilters
  • Renthal bars and Acerbis Pros
  • My rally screen
  • Andy’s IMO
  • My tank net
  • Our bashplates!
  • Reduced gearing (14/48 – never changed it back after Oued Samene)
  • I liked my Q/D Zega panniers
  • RAM mount
  • My trusty Coleman Dual Fuel 533 stove
  • Backpack hydrators (but my Platypus bladder leaked)
  • My Altberg boots – light enough to swing over and to walk in
  • Aerostich Darien Light jackets
  • Bel Ray synthetic oil – didn’t do the engine any harm
  • Thermorest mats (a three-quarter Ultralite was fine)
  • Hardwiring the GPS

Note: by now some of this gear has become obsolete or a lot better

Sub-functional mods/gear

  • Fitting heavy front springs (without doing the same on the back)
  • My GSX-R seat (barely better than the Honda plank)
  • My RK (Tagasako) chain stretched quicker than the DIDs
  • A few of my rear alt spokes snapped – the others’ OEs were OK
  • Those 10L Ortlieb water bags are hard to use and one leaked from new
  • MSR ‘RBJ’ stoves – both packed up but not designed for regular ‘desert’ fuel anyway
  • My Renthal grips – as bad as Honda (but I used ordinary gloves)
  • Canvas tool bag on my bash plate – nice idea but metal would be better
  • A lower tank with a fuel pump would lower CoG and improve handling
  • My car type oil temp gauge never worked
  • 12v cig lighter PTOs – unreliable contact on the rough terrain – hardwiring or DINs is best
  • Enlarged sidestand foot was not big enough in soft sand

Equipment failures (not including crashes)

  • Some of my rear spokes
  • Andy’s rear T63 (rock damage)
  • Jon’s tank bungs
  • One Orlieb bag
  • MSR stoves
  • Rear subframes found cracked on Jon’s and possibly Andy’s bike.

Other than that, these XRLs came back running much better than my previous Yamaha Teneres, but they were new and run on good oil.

I’ve lately been told that the Desert Riders boots I had custom made by Alt-Berg are now part of their line up.