Gravel Express: Suzuki XF650 Freewind Adventure Rally

Hessler Motorsport’s Suzuki Freewind ADV Rally…  

Available from 1997 to 2002, the Suzuki XF650 Freewind was a European-style all-rounder built around the proven air-cooled lump from the DR650 dual-sport. Though a single cylinder, the Freewind could be seen as a V-Strom predecessor:

“Cruise comfortably at 80mph, screw the pants off it on a winding road, or peer over traffic from the high seat on your way to work: the Suzuki XF650 Freewind is a versatile motorcycle that’s great value… The handling’s particularly notable.” –MCN

While the mild-mannered thumper comported itself well in a variety of conditions, it was certainly no serious off-roader…and not the most attractive machine to boot. Says Stefan Hessler of Suzuki off-road specialists Hessler Motorsport:

“Out of the box one of the ugliest Suzukis I know 😉”

Stefan has one of the strongest Suzuki off-road pedigrees in the world. After growing up in East Germany, racing enduro, and working for Simson as an engineer, he bought his first Suzuki DR Big…and the rest was history. 

Stefan began upgrading the bike and racing (and winning) international rally raids. Soon, other Suzuki off-road riders and racers were coming to him for parts and full-blown builds — and Hessler Motorsport was born, along with the Hessler Rallye Team.

“Over the years, the world’s most extensive online shop for the Suzuki DR Big and today Suzuki adventure bikes was created.” -Stefan

In the Hessler workshop, they build everything from DR350 vinduro racers to their full-blown RMR450 Dakar bike. Suzuki engineers even consulted Stefan during the development of the V-Strom, and Hessler has created quite the weapon in their Suzuki V-Strom 1050RR “Desert Express.”

Rally Monster: Suzuki V-Strom 1050RR “Desert Express”

 

Recently, their Suzuki Freewind builds caught our eye. We’re big fans of air-cooled thumpers, after all, and we’d never seen an XF650 done up this way. It all started with a buddy of Stefan’s:

“The idea comes from my friend Andre: He simply ‘threw’ three old Freewinds in front of my workshop and said: ‘You build awesome bikes, build an awesome Freewind.'”

For the yellow bike — the trickest of the trio — Stefan originally envisioned a street tracker, but then someone wanted to take it on longer off-road adventures backcountry roads.

“A BCR bike for gravel roads and light off-road terrain, ideal for beginners, shorter riders, and anyone who considers 150 kg and more than 50 hp to be suitable. (There are many!)”

They fitted a rally tower compatible with a navigation tablet and mini digital speedometer, and revamped the suspension with DRZ-400SM USD forks and a longer rear shock, achieving a very respectable 210 mm of front and rear travel — on par with a Ténéré 700.

They also gave the bike a lighter tank and other bodywork / cosmetic upgrades:

“We transform the rear end from very ugly to really cool and remove an incredible amount of unnecessary plastic and metal. The side panels are also our own design and give the bike a sleek look.”

The exhaust system consists of an FMF Power Bomb with a modified Leo Vince X3 muffler, and they installed a new airbox for the twin-carb setup. 

“Now the engine, with two carburetors (from the factory!!!), really packs a punch and even wheelies the bike in 4th gear! :-)”

 

Best of all is the weight — this Freewind now weighs 146 kg (322 lbs) fully-fueled, which is about 75 lbs lighter than the stocker and 45 lbs lighter than a DR650. Stefan claims the handling is nearly as agile as an older 500-class four-stroke enduro, and it can carry luggage to boot. 

“We’ve found the true essence of this ugly duckling and perhaps not turned it into a swan, but into a small, wild, and fun beast :-)”

 

We love to see a sturdy but nearly forgotten donor transformed into a gravel-eating workhorse, and the Hessler Freewind nails it. Even better, if you’re interested in building something similar, most of the parts on this build are available in the Hessler Motorsport shop. 

In fact, the lessons gained and products developed from modifying these Freewinds and others that followed has led Hessler to open an expansive “Freewind Freaks” shop section, loaded with parts and information.

Below is our full interview with Stefan about the build, along with more photos and video.

Suzuki Freewind 650 Rally: Builder Interview

• Please tell us a bit about yourself, your history with motorcycles, and your workshop.

I’m Stefan Hessler, born in 1966, grew up in East Germany. Only 20 kilometers away there was one of the largest manufacturers of motorcycles in the eastern bloc, the Simson company. Simson was also active in enduro sports for advertising and was very successful. Every little boy wanted to be a factory pilot – me too 🙂

We drove like crazy to the disco and also raced, all with one bike. I didn’t become a factory pilot (that’s another story) but I came back to Simson after my studies as an electronics engineer — my hobby and my job became one.

However, after the reunification of Germany, the end of Simson was in sight, and as a young engineer and in the meantime even head of the testing department, I could not stop what had determined the global economy.

On the other hand, I bought a DR Big in 1990 — for me THE bike with the greatest Dakar spirit (next to the Africa Twin) and perfect…. But I hardly rode the bike for two years after I started to improve everything about it, just like on my SIMSON and MZ before.

In 1995 I raced in my first international rally raid. I finished 8th. The rally bug that made me buy the DR Big hasn’t let go of me today either. I’ve been doing rallies non-stop to this day — I’ve won many, some as overall winners.

There were inquiries about my bikes, and I delivered — in the first few years by letter — to friends of DR Big, whom I got to know at meetings. Over the years, the world’s most extensive online shop for the Suzuki DR Big and today Suzuki adventure bikes was created. 

In our highly specialized workshop, we build special Suzuki adventure and rally raid bikes for our customers worldwide — like our Dakar bike, the RMR450 — based on the RMX450. Suzuki itself had us build a DESERT EXPRESS prototype for the V-Strom 1050 at the EICMA in Milan.

• What’s the make, model, and year of the donor bike?

We have here (the bike with the small yellow fuel tank and the blue frame) a 1997 SUZUKI Freewind. Out of the box one of the ugliest Suzukis I know 😉

• Why was this bike built? 

The idea comes from my friend Andre: He simply “threw” three old Freewinds in front of my workshop and said: “You build awesome bikes, build an awesome Freewind.”

• What was the design concept and what influenced the build?

At first, I said a street tracker would be perfect: low weight, good performance, a good-looking engine, even an aluminum swingarm! Then someone wanted to do some BCR riding with it, so we fitted a navigation tower to the front.

We knew this bike could be a chameleon. We had already built trackers, scramblers, classic and modern bikes. But then we discovered a new, much, much better transformation!

A BCR bike for gravel roads and light off-road terrain, ideal for beginners, shorter riders, and anyone who considers 150 kg and more than 50 hp to be suitable. (There are many!)

We kept the original tank on the black bikes. Thanks to KTM (with their ugly Dukes 🙂 ), you can now ride with this tank design even without a fairing 🙂 It’s the original Suzuki tank! The yellow bike kept the tracker tank. This significantly limits the range, but the handling is similar to a 520 EXC 🙂 We weigh 146kg fully fueled!

• What custom work was done to the bike?

What’s special about this conversion is that we DON’T have to modify the frame.

We mount our navigation tower at the front, compatible with an enav pad and a digital mini speedometer.

We transform the rear end from very ugly to really cool and remove an incredible amount of unnecessary plastic and metal. The side panels are also our own design and give the bike a sleek look.

We offer different seat options: original seats retain the low seat height. The yellow bike has our flat Desert Express seat – more freedom of movement, but also a higher seat height.

While the black bikes retain the original fork and suspension height (a respectable 170mm of travel), we’ve pampered the yellow one a bit more: DR-Z400SM telescopic fork, longer shock, and presto! We’re now at a decent 210mm of travel front and rear! And really good suspension components to boot!

The exhaust system is an FMF Power Bomb with a modified Leo Vince X3 muffler. For me, the best combination of power and finish. Of course, we also changed the airbox and carburetors: we disconnected the lift control valves and configured a new carburetor setup.

Now the engine, with two carburetors (from the factory!!!), really packs a punch and even wheelies the bike in 4th gear! 🙂

• Does the bike have a nickname?

It’s still available: any suggestions? 🙂

• Any idea of horsepower, weight, and/or performance numbers?

Yellow bike: 146kg / 55HP.

• Can you tell us what it’s like to ride this bike?

Take a KTM 520 – the LC4 is too big/too high for this for this comparison… a little more luggage on the EXC, a bit more… okay, that’s enough. Now no jumps, more gravel roads. Okay… that works.

Or…no, the Freewind is just as easy to handle, but it’s more stable.

• Was there anything done during this build that you are particularly proud of?

We’ve found the true essence of this ugly duckling and perhaps not turned it into a swan, but into a small, wild, and fun beast 🙂

• Is there anyone you’d like to thank?

My friend Andre for the crazy initial spark 🙂

Follow the Builder

Home: www.hessler-motorsport.de
Freewind Shop: hessler-motorsport.de/kat/freewind-area/

Social Media:

• Youtube: @StefanHessler
• Facebook: Hessler Motorsport
• Instagram: @hessler_rallye_team
• Pinterest: @stefanheler

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