Extra dirt protection for your K&N filter. Our custom made oiled-foam filter sleeve wraps snugly around the K&N filter to give a first layer of protection against dust and dirt. Oil it like you would any other foam filter.
The screws and nuts that hold the Air-box Cover on have a habit of jumping out of the air-box and running away. No idea where they go, but it is far! These cannot be purchased separately from Suzuki but we found some that are perfect replacements. This little kit includes four screws and the square nuts that go into the air-box. We recommend that you put a dab of silicone or something to hold the nuts in so they don't jump ship like the other ones did.
The DR650 has two unused 'switched' power plugs. One behind the headlight and another under the seat. This plug & pigtail assembly allows you to easily access a 12v power supply that is only on when your key switch is on.
Use it to power a GPS, charge a cell phone, run heated grips or even power a relay. Plug has leads approximately 1 foot long and a 7.5 amp miniature blade fuse.
Does not fit '22 to Current models
The 790cc Big Bore Kit includes a custom made, forged 9.5:1 piston with rings, wrist pin and circlips. A custom made multi-layer steel head gasket, OEM metal base gasket, tensioner gasket, and cam bolt lock plate and a ProCycle specific big bore cylinder sleeve.
Built cylinders with 790 sleeves installed are usually in stock, but we must have your original cylinder sent to us as a 'core'. These cores allow us to keep up this program and it is nothing more than an exchange - we give you ours, you give us yours.
This Kit Includes:
Formerly DSA, now ProCycle brand, is a plastics kit in three colors - Black, White, and Blue, as well as Blue fenders with White side panels and Black fenders with White side panels. (headlight cowl not included).
Vacuum molded, these parts are a design improvement over the stock pieces. The side panels have a crisper, more angular look than the stock parts while the front fender is shaped like the DRZ400SM OEM front fender. Big enough to be functional without wind-steering the bike like the stock fender does.
Kits include front and rear fenders, a new LED tail/brake light and license plate holder, and both side panels.
Add a fresh new side panel hardware kit and an adhesive heat shield for a fresh off the showroom floor look.
Add a stock Suzuki headlight cowl if you are doing a complete color change to your DR (must select plastic kit with head light cowl option)
A fresh set of brake rotor bolts. These bolts already have thread lock compound applied to the threads.
Stock OEM works with factory rotors, comes in a pack of 6.
For aftermarket rotors like Warp 9 or EBC front and rear sets are available.
Front comes in pack of 6
Rear comes in pack of 4.
We strongly recommend checking valve to piston clearance when installing a non-standard camshaft.
An upgrade over stock, these hard-welded premium rockers are highly recommended when upgrading your camshaft.
Kit includes all new OE adjuster screws and lock nuts.
Please see required core information below.
Geared for the do-it-yourselfer that already has a TM40 or HS40. This kit supplies everything you need to convert it for use on your bike.
Kit includes intake and air boot adapters, throttle cables, choke knob, accelerator pump nozzle, a wide selection of main and pilot jets plus a TM40 tuning manual.
Replacement socket head (Allen) screws for the OEM BST40 Carburetor. The factory screws that hold the top cap and float bowl on the stock carburetor are very easily damaged. The originals are usually installed unbelievably tight from the factory. It is common to ruin the stock screws when installing a jet kit or doing any other carburetor maintenance. Sold in a pack of four. Two for the cap and two for the float bowl.
Replacement socket head (Allen) screws in case you strip out the stock JIS heads on your TM40 bowl. The originals can be stripped out when doing any tuning or carburetor maintenance. Sold in a pack of four, all for the bowl.
Want an amazing increase in throttle response? More power over a much wider range? The Mikuni TM40 does all of that plus runs smoother at lower RPMs and pulls taller gearing with ease.
Our complete kit comes with alloy adapter rings bonded to the genuine TM40 carburetor body for a firm reliable fit in the stock air boots. We also include new low friction cables, an extended fuel screw, complete instructions along with a wide range of extra jetting for fine tuning. It even has a vacuum port for the stock fuel petcock.
The carburetor comes pre-jetted for the typical mods: performance pipe and modified air box, or we can set it up for your particular bike before we ship it out.
Instead of the tough to reach choke knob, all TM40's come with a remote choke and bracket. This makes it easier to reach the knob, especially if you have an oversize tank.
ProCycle's 14 gauge stainless steel case armor to protect your engine cases. These case guards bond to your clutch cover and stator cover with high-temp silicone (not included). Extremely tough protection from rocks. In a fall your brake pedal or shift lever can crack the engine case - leaving you stranded. Don't let it happen to you.
This nice piece replaces your plastic sprocket cover and protects your engine case from a chain derailment or failure. The 3/16" (5mm) thick steel plate is adjustable to accommodate 14, 15 and 16 tooth sprockets. Includes mounting hardware.
Hate the handlebar mounted choke lever? Can't reach the choke knob? Does your Safari or IMS tank make using the choke difficult?
Our adjustable cable operated choke knob mounts to the left side engine case and works for either the stock BST or Mikuni TM40.
Replace your handlebar mounted choke with this simple knob mounted directly on the carburetor.
Available in short or long reach.
Long reach is easier to use while wearing riding gloves.
Works for either the stock BST or Mikuni TM40.
The ProCycle seat was designed for both comfort and function. Our seat is built with a premium grade foam that is denser for those long days in the saddle, and also giving you freedom to move while standing.
The wide and sturdy seat makes long rides more comfortable. The vinyl weave helps keep you cool by letting air flow between you and the seat. The front of the seat is narrower, giving you space for your knees when you're standing, while the sides have grip so you can hold on with your knees while riding. If you choose the gel cushion option, it helps improve blood flow, prevents pressure points, and makes it easier to ride for longer without getting tired.
We will build the seat for you in-house on a new seat pan so all you have to do is put it on and go ride. Choose the heated seat option and we will add a Seat Warmer during the build process.
| Width: | 11" (279mm) |
| Height: | Same as OEM |
We start with an Excel rim, OEM hub, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike. Optional upgrades include billet a Warp 9 hub available in 5 colors and SUN rims available in 3 colors.
Our pro shop then laces and trues your wheel to perfection, giving you the highest quality custom wheel available.
Add a tire to your wheel order and we will throw in a tube and mount and balance it at no additional charge.
We start with an Excel rim, OEM hub, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike. Optional upgrades include billet a Warp 9 hub available in 5 colors and SUN rims available in 3 colors.
Our pro shop then laces and trues your wheel to perfection, giving you the highest quality custom wheel available.
Add a tire to your wheel order and we will throw in a tube and mount and balance it at no additional charge.
Complete set of 'Adventure' wheels. These are the same rim sizes as used by the BMW GS and other big adventure bikes. The 19" front and wide 17" rear will give you great twisty road handling on the pavement while still being dual-sport friendly.
We start with Excel or Sun rims, OEM or upgrade to Warp 9 hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.
Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.
Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.
We start with Excel or Sun rims, OEM or Warp 9 hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.
Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.
Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.
Ease the pressure on your wrist during those long highway drones out to where the fun begins. ProCycle has developed this kit that includes a Vista-Cruise throttle lock, a specially modified alloy throttle tube and an anchor plate that attaches to your throttle housing. Just flip the thumb lever down to apply enough friction to hold the throttle in place. Use the supplied longer screw to attach the anchor plate to your lower throttle housing bolt hole. Also included is a tension adjustment tool that you can keep on your key ring. Keep the applied tension lightly adjusted so it's easy to roll the throttle off.
Fits bikes with dual cable throttle housings.
Polyurethane drive cushions for the DR. Polyurethane has a higher abrasion, cut, and tear resistance than rubber as well as much better resistance to chemical breakdown. This will offer longer life and better damping when compared to the stock rubber cushions.
Many DR650 riders have a tough time seeing their indicator lights. How about if you moved all those lights down in front of the speedometer where you could actually see them? This bracket does just that.
The bracket relocates the rubber mounted turn signal indicator light assembly to a rigid bracket centered on the handle bar mounts. Easy to install. No wiring modifications required.
ProCycle Dashboard designed to power multiple electronic devices. It can also be used for accessory lights, heated grips or gear, whatever you like. You can also use the two pre-drilled holes to attach a RAM mount and place your phone or GPS unit on that while charging.
The dash panel is manufactured from laser cut 5/64 mild steel and powder coated black. Also included are 2 weather resistant green LED rocker switches, a voltmeter with two 4.2 amp weather resistant USB ports, a wiring harness with a built in 20 amp fuse/holder, and complete instructions. Everything you need to mount it and connect the outlets back to the battery.
**If you would like the Voltmeter & USB ports to be powered by a "key-on" power source, add the "Auxiliary Power Plug" adapter to your order and you will be able to connect the positive and negative terminals directly into the aux plug behind the cowling for a quicker and easier installation as well.
A stainless steel front fender brace. Helps stabilize your front fender.
Gives additional strength for carrying a fender mounted tool bag.
Fits on top of the fender and bolts between the fender and bottom triple clamp. Stainless steel won't rust or corrode. Includes hardware.
Requires you to drill one hole in the fender for mounting.
The ProCycle seat was designed for both comfort and function. Our seat is built with a premium grade foam that is denser for those long days in the saddle, and also giving you freedom to move while standing.
The wide and sturdy seat makes long rides more comfortable. The vinyl weave helps keep you cool by letting air flow between you and the seat. The front of the seat is narrower, giving you space for your knees when you're standing, while the sides have grip so you can hold on with your knees while riding. If you choose the gel cushion option, it helps improve blood flow, prevents pressure points, and makes it easier to ride for longer without getting tired.
Check out the seat warmer we carry. Put this in before tacking your cover in place and keep yourself warm during even the coldest rides. Nothing like toasted buns to make a ride comfortable!
Available as a Foam and Cover Kit for OEM pan. This kit DOES NOT include the pan.
| Width: | 11" (279mm) |
| Height: | Same as OEM |
Our complete foot peg assemblies. 1-3/4" lower than stock. No extra brackets that hang down below the frame. Easier on the knees. Wider platform Yamaha YZ style footpegs are stronger and give you firmer footing. Mount solid to the frame. No more 'droopy' feeling when standing on the stock pegs. Lowering your footpegs makes it easier to stand and less of a reach down to the bars when standing.
Now you can get our Low Pegs with MK4 Pivot Pegz or black Fastway ADV pegs (both Yamaha YZ pegs) installed!
Front fender from ProCycle Plastics (formerly DSA) is shaped very much like the OEM DRZ400SM front fender. Big enough to be functional without wind-steering the bike like the stock fender does. Vacuum molded, these are a design improvement over stock. These are fully compatible in any combination with the original factory plastic.
This brass fuel screw offers a longer head to give you a better hold for making adjustments. This is a nice improvement over the standard extended fuel screw. Kit includes one new screw, spring, washer and o-ring.
The Remote Fuel Mixture Screw is 5 inches longer than stock. This gives you plenty of length to easily mount in a convenient location. Will work with the stock BST Carburetor as well as the TM40 pumper Carburetor.
This kit is for those of you looking for a bit more leg and arm room in the DR cockpit. Included are ProCycle Low Foot Pegs and our oversize bars.
Our very own high flowing head-pipe is made in the USA using a CNC (computer numerically controlled) mandrel bender for an absolute perfect fit. It is a high quality 2-piece 18 gauge stainless steel head-pipe with 1 3/4" outer diameter, compared to the stock outer diameter of 1 1/2".
The SS Pro-Flow is a tested upgrade over stock that will bolt right on with no modifications needed. It is compatible with any combination muffler/mid-pipe, as well as all motor configurations of the DR650 '96-current.
Includes a stainless steel band clamp for the mid-pipe joint, clamp-on heat shield mounts, to use with stock heat heat shield and a stainless steel flange at the exhaust port mount. We recommend a new exhaust gasket when installing your new SS Pro-Flow.
Allows your bike to breathe much better giving you better response and performance.
This is a complete high-performance intake kit for the DR650 that includes our famous TM40 carburetor kit and a K&N air filter with ProCycle wrap.
Our own jet kit for the DR650 stock Mikuni BST40 carburetor. Includes the extended fuel mixture screw and stainless steel Allen screws for the float bowl and top cap. Also included are new Viton o-rings for the float. Comes with easy to understand detailed instructions and diagrams. Includes a template for modifying the air box.
Our own jet kit for the Mikuni TM40 carburetor.
Includes new main jets, pilot jets and a new needle with e-clip.
Comes with a printed Mikuni tuning manual and a jetting suggestion chart.
Not for the stock carburetor Fits TM40 conversions Only
Heavy gauge steel bracket powder coated black bolts directly to your subframe under the rear fender. Eliminates the ugly stock plastic plate holder.
Billet aluminum lowering links. Lowers the rear suspension approximately 1 inch.
By popular demand. This is our own mid-pipe adapter kit for the GSXR exhaust cans. The unique design works with both 3-bolt Hayabusa and 4-bolt GSXR mufflers. It features all stainless steel TIG welded construction with a laser cut adapter. A spring tensioned slip joint allows for heat expansion. A stainless steel hanger strap allows it to attach to your original muffler mounting point. No welding is required. Mid-pipe length is approximately 17" long.
This mid-pipe does not require a stock muffler joint gasket when used with the stock headpipe, the SS Pro-Flow, or the FMF headpipe, eliminating the hump in flow.
Don't forget a fresh seal ring gasket that fits between your muffler and mid-pipe adapter.
Muffler hanger strap and hardware to mount a GSXR exhasut can to your DR650.
Replacement muffler hanger strap for your SS1 muffler.
The Neutral Sending Unit "NSU" on the DR650 can be a problem. The factory screws tend to loosen over time. You really would not want them to get loose in your motor! The permanent solution is to safety wire them. We looked high and low and finally found pre-drilled screws in the correct length and thread pitch. Here we offer a complete kit to take care of those pesky screws.
If you don't do this, you don't have a screw loose, you have TWO screws loose!
Kit Contents:
This is all you need to not only change your oil, but protect your motor as well. We include a magnetic drain plug in the standard kit, to help catch stray metal pieces, a 5-pack of oil filters, and new O-Rings to replace any you have that may be leaking or worn.
Standard kit includes:
The Total Tune-Up Kit. All the parts you need to do a complete tune-up on your beloved beast.
What would you do if your oil cooler was damaged way out in the bush? We have a simple solution. This kit allows you to bypass the oil cooler and both oil lines and insure that the top end continues to get the oil it needs to stay healthy. Simply remove the stock oil lines from the motor and attach one end of the bypass at the head and the other end at the engine side case. Be sure to leave the original o-rings in place.
Small, light weight and easy to carry. You may never need it but if you do it will save you a lot of walking!
Fresh o-rings to ensure your DR650 stays oil-tight and leak free. Includes one of each: oil filter o-ring, filter cover o-ring and filler cap o-ring
A pair of factory OEM o-rings for the valve covers. Your valve cover o-rings live in one of the hottest parts of the engine and have a pretty short life. Replace them on your next valve adjustment to prevent oil leaks.
For those people who have been wishing for a dual petcock setup for their Acerbis 5.3 and 6.6 gallon fuel tanks. Install this kit to get the last bit of fuel from the right hand side of the tank without tipping the bike on its side. Includes the right hand fuel valve, o-ring, screws, tee fitting, fuel hose and spring action hose clamps. You will have to drill the hole in your tank for the petcock standpipe. For Acerbis tanks only.
The ProCycle rack system is designed and manufactured by dual sport riders that know what it takes to create a durable and versatile luggage rack.
Our racks allow for easy installation of both soft and hard luggage.
See the linked instructions for how-to videos.
ProCycle Plastics (formerly DSA) Rear Fenders include LED tail/brake light and license plate holder. Vacuum molded, these parts are a design improvement over stock.
Lost your side panel hardware? You aren't the first! We've got replacements. Two side panel screws, two special washers and the rubber insert that protects the side panel from the muffler.
Replacement side panels from ProCycle (formerly DSA). These pieces are fully compatible in any combination with the original factory plastic. These side panels have a crisper, more angular look than stock. Vacuum molded, they are a design improvement over the stock panels.
Sold in pairs
Does not include heat shield. Depending on your application and preferences, more than one optional heat shield may be useful.
The ProCycle side rack is designed and manufactured by dual sport riders that know what it takes to create a durable and versatile luggage rack.
Our racks allow for easy installation of both soft and hard luggage.
Side racks only, top rack sold separate.
Compatible with the following top racks:
ProCycle rack installation requires removal of the stock grab bars. Turn signal brackets will be needed if using a top rack that doesn't offer turn signal mounting holes.
Construction
Minor installation marks on mounting points. Includes all hardware and instructions. Sold as is.
The ProCycle side rack is designed and manufactured by dual sport riders that know what it takes to create a durable and versatile luggage rack.
Our racks allow for easy installation of both soft and hard luggage.
Side racks only, top rack sold separate.
Compatible with the following top racks:
ProCycle rack installation requires removal of the stock grab bars. Turn signal brackets will be needed if using a top rack that doesn't offer turn signal mounting holes.
Construction
Here we have right side plate that bolts to our ProCycle Side Racks for mounting your RotoPax fuel or water containers.
Limited quantity available for right side only.
ProCycle side panel guards to keep your saddlebags from fouling the side covers. Constructed from mild steel tubing that is powder coated black for nice long lasting good looks.
Add your favorite set of saddlebags for a very economical luggage solution.
Guards only, saddlebags sold separate.
The ProCycle SS1 muffler was designed so this existing spark arrester will fit right in. This is also the same unit that is often adapted to the GSXR 40F0 muffler. It fits FMF exhaust as well.
Eliminates the stock speedometer drive for those who have replaced their stock unit with a Vapor or something similar. Light weight billet alloy spacer and a seal to protect your wheel bearings.
Our Tool Tube mounts in place of the little stock tool carrier. The tube is made from 3 1/2" O.D. ABS pipe. It's held by 3 strong powder coated steel straps. Both ends are sealed with waterproof expanding plugs. This is the ideal way to carry those items you always want to have with you on every ride. Tube is approximately 13" long.
You can now order your Tool Tube with a Locking End cap, mini padlock and keys included, on the exposed end.
If you already have a Tool Tube you can order just the Locking End Cap and lock.
Does not fit if your bike is equipped with the new emissions system. The charcoal canister prevents the tool tube from being mounted properly.
Have your tank cushions worn out over the years? Have you lost one or more while working on your bike? We have new upper and lower tank cushion rubbers.
This kit includes the original hardware, upper, and lower cushions.
This is a simple three piece kit you can install in minutes that cleans up the stock DR rear-end.
We use the DR250 taillight that fits perfectly into the pocket of the stock taillight on the DR650 fender. It is smaller, looks great and is out of harms way more than the stock unit. It is a total 'plug-n-play' as the wire pigtail plugs right into the DR650 harness just like stock.
Then we use a small LED light to keep you legal and illuminate your license plate, which gets mounted to our custom stainless steel bracket that is powder coated black, eliminating the stock ugly plastic mount.
Kit includes:
Our ProCycle top rack is designed and manufactured by dual sport riders that know what it takes to create a durable and versatile luggage rack.
Our racks allow for easy installation of both soft and hard luggage.
Top rack only, side racks sold separate.
An optional add on to your ProCycle Top Rack to relocate your rear turn signals with ease.
This 3rd gear set is made for us by Nova Racing Transmissions in England to replace the fragile stock third gear set. These folks build complete transmissions for World Superbike teams among others, so we believe them to be highly qualified to build this set of replacement gears.
These gears are made from a high quality special alloy steel and then heat treated and superfinished. The mainshaft drive gear and the countershaft driven gear are sold only as a set.
Mounts to existing signal brackets to move the front turn signals up and forward to clear the bigger 5.3 & 6.6 gallon Acerbis tanks.
Premium cylinder head upgrade.
Features CNC machined port shapes, larger high performance valve seats and custom made valves. Valve sizes are increased from the tiny stock 33mm intake & 28mm exhaust to 36mm intake & 32mm exhaust.
This is not a radical modification. These bigger valves bring the valve sizes up to what would normally be found on other brands of 650 singles.
We strongly recommend checking valve to piston clearance when installing oversized valves.
This option is ideal for those who desire the least amount of down time to install this engine upgrade.
This kit includes a core charge that allows us to ship your kit before we receive your stock cylinder head core in 'good' condition. More details regarding core exchange linked below.
4 custom made valves and 4 'Nickel Aluminum Bronze' valve seats. Valve sizes are 36mm intake (up from 32) & 32mm exhaust (up from 28). Requires professional installation.
We strongly recommend checking valve to piston clearance when installing oversized valves.
Modern technology for the DR650s charging system. Mosfet style regulators produce less heat, are more efficient and last longer than old tech 'shunt style' regulators. Regulator is made by Rick's Motorsports, and includes a ProCycle adaptor bracket to fit into the existing space on the bike.
This regulator / rectifier is Lithium compatible.
Genuine SKF wheel bearings. Single row deep groove ball bearings with seals on both sides are particularly versatile, have low friction and are optimized for low noise and low vibration, which enables high rotational speeds. They accommodate radial and axial loads in both directions, are easy to mount, and require less maintenance than other bearing types. The integral sealing can significantly prolong bearing service life because it keeps lubricant in the bearings and contaminants out.
Includes all wheel bearings and new dust seals.
The rear kit includes the bearing and seal for the cush drive hub (sprocket carrier). All bearings are sealed on both sides.
