DR 650 with OEM rack Installation ('96-'17)

 

Items provided:

 

•Saddlebags

•ABS rack (comes pre-assembled)

•Hardware (metric) 23 pieces [Figure 1]

A B C D E
130mm 100mm 60mm 85mm 100mm
washer washer washer washer washer
shim shim spacer spacer shim
spacer spacer washer locknut spacer
locknut washer     locknut
R. Rear R. Front Left Front Left Middle Left Rear

 

Tools needed:

 

• Drill and 5/16" or 8mm bit

• Ratchet

• 13mm wrench/socket

• Allen wrench

 

Assembly required: Mount the ABS rack to the subframe of the DR with the provided hardware. Then secure the saddlebags into place.

 

Note: Spacers/shims included with rack are black. White spacers pictured are for photo purposes only.

 

Detailed instructions are shown below.

 

 

Download print version:

 

DR650SEinstallation1.doc

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Step 1 - Remove Stock Components:

 

The front two bolts holding the stock rack on need to be removed in order for the new hardware to be mounted. The locations of the two bolts to be removed are labeled C and B in Figure 2 and 3. Remove the helmet lock and drill the front hole out to an 8mm diameter (Figure 2). This will provide bolt E a place to fasten.

Step 2 - Install ABS Rack:

 

You will find that the ABS rack will only fit one direction. The top front follows the curve of the seat and the bolt holes will only line up if the ABS rack is positioned that way.

 

Install the hardware provided loosely at first until all the bolts have been started. A medium strength thread locker (ex. Loctite® Blue 242) is advised on bolts with no locknut. B and C hardware should be installed first. B has a shim on the outside of the rack with the angle against the rack and wide end facing up. The B and C spacers should have the angled side against the inside of the ABS rack with the long end facing down. The B and C spacers should be mounted in between the ABS rack and the stock Suzuki rack with a washer seperating them. It is important that the B and C washers are placed in between the spacer and stock Suzuki rack. The spacers could be damaged if the big washers are not placed properly. Refer to Figure 4 for proper placement.

 

Next install A, D, and E. The bolt head, washer, and shim should all be on the outside of the ABS rack for A, B, and E (D and C have no shim). Position the A shim and spacer like B. The D spacer will fit into the aluminum brace attached to the ABS rack with the angled end against the subframe and long side facing down. The E shim angled side will be against the outside of the rack with the wide end facing toward the front of the bike. The E spacer angled side will set against the inside of the rack with the longer side facing toward the rear.

 

With all of the hardware lined up with the appropriate holes, you can start tightening up the bolts. The spacers will naturally want to rotate so the angled end matches the slope of the rack. You may need to manually rotate each spacer so the two angles fit better.

Step 4 - Securing The Saddlebags:

 

Fisher Saddlebags™ do not use long straps with hooks to secure the saddlebags because of the potential for the strap to come loose and get caught in the wheel or chain. Instead the saddlebags are secured to the ABS rack with sewn in pockets and turn-buckles.

 

The side saddlebags have a front inside pocket that slips over the front of the ABS rack. There is a single turn-buckle at the front of each saddlebag on the inside (Figure 6). There is also a flap in the back that secures to the turn-buckles mounted on the rack. Figure 7 shows this in detail.

 

The top bag is secured by a pocket in the back that slips over the back end of the rack. Since it is sewn to the other two bags, it needs no other fastening devices.

 

With the rack bolted on to the subframe, the bags will be easy to put on. The simplest way to put the bags on is to:

 

1. Slip the top bag pocket over the back of rack
2. Secure the front left saddlebag turn-buckle
3. Slip the left saddlebag pocket over the rack
4. Repeat steps 2 and 3 for right saddlebag   
5. Fold the back flaps over the 4 turn-buckles and

....twist each turn-buckle 90 degrees

 

The ABS rack can be installed or removed in a few minutes.

 

The saddlebags can easily be installed or removed in less than a minute.

 

*If there is a lot of weight in the saddlebags, it is a good idea to strap a bungee cord around to keep the bags more stable.

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