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DR650

The Suzuki DR650 is a long-standing model in Suzuki's lineup, introduced in 1990 as a replacement for the DR600 model. The DR is a 644 cc, 4-stroke, single cylinder, SOHC, 4-valve, air/oil cooled dual-sport motorcycle with a counterbalanced engine that develops 36 horsepower. It has a 13 L fuel tank.

Chain Size:               Front Sprocket:                 Rear Sprocket:               Front Tire:               Rear Tire:                   Spark Plug:

520x114 ('90-'95)

525x110 ('96-Cur)

16T ('90-'95)

15T ('96-Cur)

42T ('90-'95)

42T ('96-Cur)

90/90-21 120/90-17

DPR9EA-9 ('90-'95)

CR10E ('96-Cur)

Featured Products

Years in development, Yenkro Adventure Rally Fairings have been designed from the ground up to withstand even the most unforgiving terrain and now the gen 2 kit takes it to the next level. Battle-tested in conditions that only the Australian outback can muster, this fairing is a must for adventure riders from all corners of the globe.

Side Panels are Optional and Sold Separate, they work with Acerbis 6.6 gallon (25L) tank only. Available in either black or white.

Can be purchased with or without side panels.

Standard kit includes:

  • The main tower assembly with all the mounting brackets to suit your bike
  • Speedo bracket which also holds the stock wiring loom.
  • 1 Short screen
  • 1 Tall screen
  • Hella halogen lights (upgrade to led by adding the upgrade option to your cart)
  • Qc3 usb charge socket
  • Plug and play wiring for lights and usb.

The standard lighting kit is a pair of hella 60mm projectors, one for high and one for low, these are 60w halogens and are DOT and ADR approved.

Choose Kit
Add Side Panels for Acerbis 6.6 (25L)
Please contact us for availability information
$1,229.95

Engine

Wiseco 96mm/+1.00 mm piston with rings, wrist pin, circlips, head gasket, and base gasket. 

Requires your cylinder to be bored to fit the larger piston.

All Wiseco Pistons are forged from high silicon, low expansion aluminum which offers superior strength, reduced weight, improved heat transfer, and longer life.

Diamond turned finish from one of the many CNC computer controlled turning centers guarantees you a perfect finish with no size variation. Wiseco pistons can be installed in any of today’s cylinder bore compositions

Wiseco’s state-of-the-art computerized manufacturing facility is dedicated to supplying both the high-perfomance racer and recreational enthusiast with the finest forged piston available in today’s market place.

Ships in 1-2 weeks
$268.95

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:

  • DR790 Big Bore SLEEVE ONLY (requires your cylinder to be bored and sleeve pressed in.  Your local machine shop is the best place to ask for this service.)
  • Steel Base Gasket
  • Steel Head Gasket
  • Cam Sprocket Plate
  • Tensioner Gasket
  • 110.6mm DR790 Piston
  • Instructions with DR790 Stickers
Sleeve/Cylinder Options
Ships same business day
$749.95

Raises compression from stock 9.5:1 to 10.5:1 for more power, torque and snappier engine response. The high quality forged piston from JE is almost a full ounce lighter than the stock cast piston. This makes for less vibration and a smoother running motor. Includes rings, pin, clips, and top end gasket set with valve stem seals and metal base gasket. Fits the standard size stock bore.

Ships same business day
$284.95

Raises compression from stock 9.5:1 to 10.5:1 for more power and snappier response. The high quality forged piston from JE is almost a full ounce lighter than the stock cast piston. This makes for less vibration and a smoother running motor. Fits the standard size stock bore.

Ships same business day
$241.95

The Complete Top End Performance Kit includes:

10.5:1 compression JE piston with rings, wrist pin and circlips (the actual measured stock compression is only 8.7:1).
Stage 2 Web Cams high performance camshaft for more power (reground from brand new OEM Suzuki camshafts).
Top end gasket set with metal base gasket.

We strongly recommend checking valve to piston clearance when installing a non-standard camshaft.

Please contact us for availability information
$899.95
DR650 '96 - '25

This is the little rubber plug on the right hand side of the cylinder head. Replace this plug to avoid having an oil leak after disassembling your top top end.

Ships same business day
$6.95
DR650 '96 - '25

Solid reliability and easy installation. This manual tensioner is a good upgrade for any modified motor, especially if it is ridden hard.

A new gasket is included.

Ships same business day
$76.95
DR650 '96 - '25

A Suzuki OEM gasket for the Cam Chain Tensioner. You are going to need it if you work on your starter motor. It is not a good idea to re-use this gasket. If it blows out, it will dump a large amount of oil onto your right foot.

Ships same business day
$4.95
DR650 '90 - '25

Your automatic cam chain tensioner is spring loaded. This can make it difficult to install as it wants to extend before you have it bolted into place. This handy tool will back off the cam chain tensioner mechanism and hold it for you. No more awkward 3-handed contortions are required to get the tensioner installed.

Ships in 3-5 business days
$99.95
  • Our own #190 cam profile offers more lift to give better low-end and mid-range punch and more duration to keep the motor pulling hard in the upper RPMs.
  • Our performance cams are reground from OEM camshafts - no core charge or return required.
  • We recommend a high compression or big bore piston to get the most out of your performance camshaft.

  We strongly recommend checking valve to piston clearance when installing a non-standard camshaft.

Please contact us for availability information
$659.95

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.

Big Valve Heads are sold only on an exchange basis. We need your stock head for the next batch of modified heads.

  We strongly recommend checking valve to piston clearance when installing oversized valves.

Please contact us for availability information
$1,299.95
Universal fit. May require additional adjustment or modification.

K&L® shims exceed the maximum of the Apparent Rockwell Hardness "C" scale. Shims average 47.0 compared to the 46.0 maximum.

These kits fit multiple brands and models, please verify correct size for your model before purchase.

13mm diameter - Includes two valve shims of each size 2.30, 2.40, 2.50, 2.55, 2.60, 2.70, 2.80, 2.90, 3.00 and 3.10.  In a shim box.

20 shims in total. From K&L.

KAWASAKI

Choose Shim Size
Ships same business day
$219.95
DR650 '96 - '25

A set of four high quality valve stem seals.

Ships same business day
$26.95

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.

Ships same business day
$379.95
DR650 '96 - '25

Ride in warm temperatures a lot? Worried about your motor oil just getting too hot? The Trail Tech Universal Fan Kit mounts up to the backside of the DR's oil cooler to draw cool air across it and keep those oil temps down. An electronic temperature sensor mounts to the fan, no need to cut any fluid lines, and automatically turns the fan on when needed to keep the temperature in the optimum range.

The activation sensor can be set wherever you like to keep the temperature right where you want it. Backlit for easy viewing anytime it also includes a volt meter.

Kit Contents

  • 4 inch SPAL fan
  • TTV Temp Meter
  • Temperature Sensor
  • Complete Wire Harness
Ships same business day
$219.95

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!

Ships same business day
$44.95
DR650 '96 - '25

This kit of O.E. Suzuki O-rings replaces your leaky, weepy, and brittle O-rings that fit between your DR's oil cooler lines. You get 4 O-rings in this kit to replace both feed and return line O-rings.

If you're noticing oil leaking or creeping around your oil cooler, oil cooler lines, or engine, you may have one or more failed / failing oil cooler line O-rings. Replace them now before they completely fail and you run your motor dry of the precious oil it needs to operate properly.

Ships same business day
$17.95
  • Protect your DR650 from overheating.
  • Inline temp block kit works with Trail Tech computers Striker, Vapor, Voyager, Voyager Pro, and all TTO temp meters. 
  • Installs between the oil cooler and top oil supply line, giving a cooled oil temp reading.
  • Includes 3 new o-rings, and 2 longer bolts, as well as the Trail Tech m6x1.0 temp prob.
Ships in 1-2 business days
$54.95
DR650 '96 - '13

This is a genuine Suzuki part. We recommend installing a countershaft seal retainer to prevent the countershaft seal from popping out while riding.

Choose Model Year
Ships same business day
$10.95
DR650 '96 - '25

OEM Suzuki seal retainer for the DR650. Simple insurance against your countershaft seal popping out of its bore.

This is not a common problem but for those folks who have had the seal come out it has proven to be quite difficult to get it to stay in place. This steel retainer eliminates any possibility of the seal coming out and ruining your day by coating your rear tire with oil.

Ships same business day
$22.95

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:

  • 2 drilled stainless steel screws
  • Plenty of safety wire
  • Wire twisting tool
  • New lock tab for the clutch hub
  • New clutch cover gasket
Ships same business day
$53.95

The starter bushing in the DR650 leads a tough life. Exhaust heat and minimal lube from the factory take their toll. Warp 9 has a high quality solution - a billet starter cover with a sealed ball bearing.

  • CNC machined starter endcap
  • Black anodized for good looks
  • High Speed Abec 3 double sealed roller bearing installed
  • Reduced amperage needed to start bike
  • Brushes will have extended life
Add Starter Brush Kit
Ships same business day
$68.95
DR650 '96 - '25

New starters that are manufactured to meet or exceed OEM specifications. Pull out your old starter, put in this new one and go riding. These units are built to provide a longer life than the OEM unit with these features:

  • The armature is insulated for rust and corrosion protection
  • Rubber seals on the top and bottom of the unit ensure a dry operation
  • 90/10 copper bushings
  • Extended shaft replaces long or short shaft OEM starters
Ships same business day
$149.95
DR650 '96 - '25

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.

Ships same business day
$499.95
DR650 '96 - '25

The long awaited Wide Ratio Transmission from Nova Racing. Now you can have your trail gearing without giving up your highway gearing.

Both sets are lower than stock in 1st and 2nd gear and taller than stock on 3rd thru 5th gears. Not only will Nova give you better gear ratios but the high quality components will shift smoother and engage more solidly. The tables below show each gear ratio and the original OEM ratios for comparison.

To help put the ratio changes into perspective switching from the OEM 15T to a 14T sprocket lowers the gearing by 7.1% in all gears. Switching from a 15T to a 16T raises the gearing by 6.6% in all gears.

Stock  Gearing  Ratio 
1st12/292.42:1 
2nd16/261.63:1 
3rd21/261.24:1 
4th21/211.00:1 
5th23/190.83:1 

The "A" gear set has an 8% wider gear ratio spread than stock.

"A" Set  Gearing  Ratio  From OEM  
1st12/302.50:1-3.3%
2nd16/271.69:1-3.7%
3rd19/231.21:12.3%
4th22/210.95:14.8%
5th24/190.79:14.3%

This product is not eligible for promotional pricing or discounts

Choose Gear Set
Please contact us for availability information
$1,699.95

The EXP disk is the magic ingredient behind the functionality and benefits of Rekluse auto clutches. About 10 years ago, Rekluse introduced an innovatively redesigned version of its revolutionary auto clutch technology with EXP 3.0. The years of racing, testing and development since have led to Rekluse’s most refined auto clutch experience yet; Introducing EXP 4.0.

No More Stalling:
Using principles of centrifugal force, EXP technology automatically engages and disengages the clutch based on engine RPM. With EXP, riders can start and stop without touching the clutch lever. EXP automatic clutch technology provides riders precision throttle control, maximum traction and confidence to maneuver any obstacle on the track, trail, or road.

Less Arm Fatigue:
You don’t have to clutch as often, which preserves your arm for longer rides.

Tunable to Fit Your Riding Style:
Each auto clutch is optimized for each bike model as it comes from the factory, and EXP 4.0 has been developed and tested in a wide range of late-model motorcycles. However, everybody rides differently, so they made sure EXP technology can be fine tuned. They offer different spring and wedge options so riders can further adjust their clutch’s performance. Some riders like the clutch to engage just above idle, while others like later engagement.

Clutch Lever Is Still Functional At All Times:
It is possible to fully override the auto functionality at any time. You can pull the lever in, build RPMs, pop the clutch out and raise the front tire just like normal.

Have More Fun:
You don’t have to worry about covering your clutch to prevent stalls all the time. You are free to relax and enjoy the ride, having one less thing to think about.

 

Ships same business day
$749.95
DR650 '96 - '25

Barnett high performance clutch set. Includes 8 Kevlar friction plates, the 7 'loose' steel drive plates, stronger springs and a high quality clutch cover gasket.

Ships same business day
$209.95
DR650 '96 - '25

Top quality friction plates, steel plates and heavy duty springs from Dunlop. Don't forget to use a new clutch cover gasket.

Ships same business day
$209.95
DR650 '96 - '25

Complete set of friction plates, HD springs and steel separator plates prevent premature driven plate wear, oil muddying and loss of stack height. Built with swaged aluminum carriers that spread the load on the clutch basket and prevent clutch basket "dogging". Anti-swell, alloy impregnated heavy-duty facings for smooth clutch action. Allows modulation, unlike paper clutches which tend to snatch. Don't forget to add a fresh gasket.

Ships same business day
$169.95

This kit includes one OEM drive plate retaining wire & one OEM inner steel drive plate.

If you've ever changed the clutch on a DR650 you will be familiar with the extra steel plate at the bottom of the stack that is locked in place by a very thin metal wire.

Generally, when you do a clutch replacement on the DR650, you do not need to remove or replace these items. If you do need to (or if you have already) you will come to realize this wire is not very strong and is prone to breaking if not treated with care during the removal / installation process.

Ships same business day
$16.95

In this kit you will get 4 factory replacement bolts to replace any broken or damaged clutch pressure plate bolts on your DR650.

It can be easy to over torque these bolts if not done properly. If one of these bolts is damaged on your DR650, we highly recommend replacing all 4 to prevent any future failures down the trail.

Ships same business day
$9.95

This is an extended version of the stock DR650 clutch release arm that is manufactured by Suzuki.

Upgrading to a longer clutch release arm will lighten the pull of the clutch lever through means of increased leverage. This means less fatigue, quicker clutch engagement, easier clutch modulation and longer rides.

The extended clutch arm will not offer a drastic change in clutch pull. If you're looking for a major change in clutch pull at the lever, we recommend getting a Magura hydraulic clutch kit.

Ships same business day
$31.95

Barnett clutch springs are made from the finest materials available.

Heavy Duty Barnett clutch springs are pre-set, shot-peened, and heat treated for performance and durability.

Ships same business day
$18.95

Dragging clutch? Hard to find neutral? Maybe it feels like it doesn't fully release. These problems can be caused by worn thrust washers in the clutch assembly. Most DR650s show wear on these items. Kit includes #1, #2 and #3 in the diagram.

Ships same business day
$42.95
DR650 '96 - '25

This is one of the few plastic parts on the DR650 that can ruin your day if it breaks or fails on you. This gear helps drive the oil pump to circulate oil throughout your entire motor, without it, your motor will fail entirely. The idler gear is not known for being a common failure point in the DR650 motor but, it has failed riders in the past. Usually in the form of a broken gear or stripped teeth. Upon inspection, look for any kind of crack, chipped or missing teeth on the gear. It is not a complicated repair to swap an old gear for a new one, as the best time to replace it is when you've opened up the clutch side case cover for another repair i.e., (NSU screws or clutch hub bushing replacements). This is an O.E. Suzuki part.

Ships same business day
$28.95

Complete set of engine gaskets and oil seals. Includes the addition of a factory Suzuki metal base gasket. A metal base gasket is essential because paper base gaskets will fail in the DR650.

Kit Includes:

  • Factory Suzuki metal base gasket
  • Head gasket
  • Clutch cover gasket
  • Cam chain tensioner gasket
  • Mag cover gasket
  • Exhaust gasket
  • All oil seals
  • All o-rings
Add Gasket Remover
Ships same business day
$114.95

Top end gasket set with the addition of a factory Suzuki metal base gasket. A metal base gasket is essential because paper base gaskets will fail in the DR650.

Add Gasket Remover
Ships same business day
$54.95
DR650 '96 - '25

High quality clutch cover gasket. If you are servicing your clutch, a new gasket will prevent oil leaks.

Add Gasket Remover
Ships same business day
$17.95
DR650 '96 - '25

High quality left side case gasket. If you are servicing your stator or starter clutch gears, a new gasket will prevent oil leaks.

Add Gasket Remover
Ships same business day
$17.95

Billet plugs for your left side case. Includes both the timing mark plug and the crankshaft access plug.

Choose Color
Ships same business day
$39.95
DR650 '96 - '25

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

Ships same business day
$8.95
DR650 '96 - '25

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.

Ships same business day
$11.95
DR650 '96 - '25

This is all you need to not only change your oil, but protect your motor as well. We include a magnetic drain plug, to help catch stray metal pieces, a 10-pack of oil filters, and new O-Rings to replace any you have that may be leaking or worn.

  • Magnetic Drain Plug
  • O-Ring Kit
  • 10-Pack of Oil Filters
Ships same business day
$57.95

The Total Tune-Up Kit. All the parts you need to do a complete tune-up on your beloved beast.

  • Valve Adjustment Wrench
  • Feeler Gauges (.004" & .008")
  • Breather Filter
  • 10-Pack of Oil Filters
  • Magnetic Drain Plug
  • O-Ring Kit
  • Air Filter
  • Spark Plugs
Select Package
Please contact us for availability information
$134.95
DR650 '96 - '25

The PSR Oil Filler Caps are CNC machined from high quality aluminum and come with an E-clip that is already safety wired to a mounting tab. The wire is covered with silicone tubing that will not melt or discolor. Available in silver, black and gun metal.

Choose Color
Ships in 1-2 business days
$31.95

New from the folks at Warp 9, a CNC billet machined Oil Filler Cap. Available in Blue or Black and it includes a new O-ring! To make removal as easy as possible, the center tab takes a 12mm wrench perfectly, or a 1/4" ratchet drive in the center! On each end of the center tab is a drilled hole should you find it necessary to safety wire your filler cap in place.

Choose Color
Ships same business day
$19.95

Superior Filtration:

This should be the last oil filter you will ever buy. Made from laser cut, medical grade, 304 stainless steel micronic filter cloth, this filter provides 200% more filter area than other filters in many cases. Most good paper filters will pass particles in the 90 to 95 micron range, and some tested, as much as 300 microns. Sand is about 125 microns and a white blood cell approximately 25 microns. Scott's stainless filter catches items down to 35 microns "absolute". The pleat seam is welded, able to withstand up to 600 degrees, not glued, like paper filters.

Ships same business day
$87.95

Providing unbeatable performance and exceptional value, Hi-Flo is the best-selling brand of aftermarket filters for motorcycles, scooters, and ATVs worldwide. The filters are also supplied to original equipment manufacturers as well as private label brands.

You pay $3.70 per filter with our value 10-pack!

Ships same business day
$36.95
DR650 '96 - '25

It is a good practice to replace your sealing washer with every oil change. These 10 piece kits are made up of 5 Copper washers and 5 Aluminum washers. The manufacturer recently decided to make half of the kit Copper washers as that is the material of choice for many OEM manufactures. This gives you the opportunity to decide which you prefer, but either will work great at creating a leak-free seal between the case and the drain plug.

Ships same business day
$6.95
DR650 '96 - '25

Extra protection for your motor. A strong magnet at the end of the plug picks up metallic flakes in your oil.

Ships same business day
$16.95
DR650 '96 - '25

Direct replacement for old or broken stock spark plug caps.

Spark plug caps contain a resistor that can burn out with age. Fresh caps ensure your motor gets a strong spark.

  • Sold in pairs.
  • Adaptable thread size
  • 5k Ohm
  • Allowable wire diameter 7 mm-8 mm
  • 120° elbow
  • Spark Plug Resistor Cover - 10/12mm
Ships same business day
$12.95
Universal fit. May require additional adjustment or modification.

Hardened chrome vanadium steel with built in rubber insert to hold spark plug steady.

Thin wall bi-hex sockets designed to access narrow spark plug holes.

Fits 3/8" square drive and hex drive, 14mm, 16mm, 18mm, 21mm.

Choose Size
Ships same business day
$14.95

Keep your motor running right with a fresh plug.

A Dual Electrode spark plug will last longer than a single electrode plug because the wear is shared between the electrodes.

Choose Spark Plug
Ships same business day
$24.95
DR650 '96 - '25

E3 Resistor Spark Plugs

  • Unique electrode shape maximizes the power created by the spark plug – Diamond Fire technology
  • Electrode is a combination of performance and technology that results in an improved flame kernel shape
  • This flame front ignites the bulk air/fuel mixture faster, moves heat into the combustion chamber faster and creates a more localized pressure front for faster pressure rise during the cylinder power stroke
  • The result is more complete combustion and an improvement in engine performance
  • A truly premium performance plug
  • Sold individually, unless otherwise stated.

(Pair)

Add Anti-Seize
Ships same business day
$19.95
DR650 '96 - '25

Iridium spark plugs are made with premium quality materials.

Iridium plugs last longer than standard ones, meaning you won't have to replace them as often.

  • The ultimate in the evolution of spark plug technology and performance from an industry leader
  • The iridium electrode is 25% smaller than a platinum electrode, and it's just 1/4 the size of a conventional nickel electrode
  • Ultra-small diameter center electrode reduces voltage requirement and extends ignition system life
  • Metal shell plating has enhanced anti corrosion qualities

Sold individually, unless otherwise stated.

Choose Spark Plug
Add Anti-Seize
Ships same business day
$23.95
DR650 '96 - '25

Keep your motor running right with fresh spark plugs!

NGK is one of the world's largest manufacturer of spark plugs, whose products are used as original equipment (OE) on countless motorcycle and automobile models.

  • High-quality materials and superior construction for serious power and reliability
    • Pure alumina silicate ceramic insulator provides high strength and better heat transfer
    • Deep-seated copper core for a wider heat range
    • Nickel alloy tip for longer life
    • Trivalent metal plating provides superior anti-corrosion and anti-seizing properties
  • Choosing the right high-quality plugs prevents fouling from running too cool and preignition from running too hot
  • NGK plugs available for almost every application and riding style
Add Anti-Seize
Ships in 3-5 business days
$17.95

Clymer motorcycle repair manuals are written specifically for the do-it-yourselfer. Whether it's routine maintenance or more extensive repairs involving engine and transmission disassembly, Clymer repair manuals provide all the information you need about your motorcycle. With step-by-step procedures, detailed photography and extensive use of exploded views, each manual is based on the complete disassembly of the machine. Unlike OEM manuals, which are purposely designed for the professional technician with an impressive array of specialized tools, equipment and knowledge, Clymer manuals are designed for the first-time user.

The DR650 manual features 278 pages of color wiring diagrams, illustrations and photographs. There are 15 chapters, ranging from general information and troubleshooting to brakes, suspension and full color wiring diagrams.

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$51.95

The genuine factory shop service and repair manual. This is the reference manual Suzuki dealers use in their service departments. It has all the necessary info to do any maintenance or repairs to your DR650.

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$96.95
Universal fit. May require additional adjustment or modification.
  • Contains degree wheel, standard unit indicator, adjustable magnetic stand, and three positive stops (10 mm, 12 mm and 14 mm threads)
  • Can be used to install and adjust timing of any cam
  • Wooden carrying case
Ships in 3-5 business days
$315.95
DR650 '96 - '25

Need to remove your clutch assembly to get at that dreaded neutral safety switch? This holder is the quickest and easiest tool out there to get a grip on that hard to handle hub. Laser cut to the exact pattern that EBC makes their clutch plates from, it makes loosening and re-tightening the clutch nut easy. All of that and no worries about doing any damage to your expensive clutch hub.

Bottom line, if you have to hold your clutch hub to remove it, there is no better way to do it.

Ships same business day
$28.95
Universal fit. May require additional adjustment or modification.

Made from medium carbon steel with hardened jaws. It features spanner pins and the jaws open up to 5" wide. It's ideal for holding clutch hubs, flywheels, gears, sprockets, etc. Made by Motion Pro.

Ships same business day
$32.95
Universal fit. May require additional adjustment or modification.

This tool is designed to separate vertically split crank case halves on two and four stroke engines. Adjustable arms allow it to be used on multiple bolt patterns found on a variety of makes and models of motorcycles. Industrial grade steel construction with black oxide finish for long service life. Comes with 8mm mounting bolts and 6mm adapters. Protective carrying case included.

Backordered: Waiting for stock from suppliers to fulfill orders placed on or after July 2024
$112.95
DR650 '96 - '25

Special tool to remove the flywheel from the end of the crankshaft.

Ships same business day
$79.95
Universal fit. May require additional adjustment or modification.

For easy removal of recessed oil filters.

Conical point screws pierces and grabs the metal end cap of the filter.

reduces potential damage to the engine cases.

NOT for use on re-usable oil filters.

Ships same business day
$13.95
Universal fit. May require additional adjustment or modification.

A 3-pack of easy to apply strips measure the temperature of engine, suspension, and radiator components. Temperature range 146° to 248°

Ships same business day
$14.95
Universal fit. May require additional adjustment or modification.

Thread Chasers are designed to clean and re-cut damaged aluminum threads.

This kit contains the two sizes most common on metric motorcycles, M6x1.0 and M8x1.25.

Thread Chasers also remove dirt and metal shavings that become captured in thread grooves.

Uses 8mm or 10mm hex sockets, a Must for all tool kits.

Ships same business day
$5.95
DR650 '90 - '25

A 'wrench style' tool to turn the 'square top' tappet screws. The wrench does a better job of holding the adjuster screw still while tightening the locknut. Slim and flat, this tool is easy to carry in a tool pack.

Ships same business day
$14.95
DR650 '96 - '25
  • Allows precise valve lash adjustment without disturbing the setting when the lock nut is fastened
  • Knurled knob on adjuster drivers ensure a precise and secure grip
  • Integrated repositionable wrench handle holds the lock nut while the drivers are used to loosen or tighten the valve adjustment screw

Set includes:

  • (1) 10mm steel socket wrench
  • (1) 3mm square tappet adjuster
Ships same business day
$34.95
Universal fit. May require additional adjustment or modification.
  • 26 straight blades
  • SAE and metric markings
  • Check for clearance on valves, ignition points etc.
  • Includes 26 blades varying in thickness from .0015"/.038 mm to .025"/.635 mm
Ships same business day
$12.95

Two feeler gauges with angled ends to make checking the clearances easier. Stock valve clearances are .004" intake and .008" exhaust (.10mm in. and .20mm exh.)

Backordered: Waiting for stock from suppliers to fulfill orders placed on or after April 2024
$12.95

Fuel and Intake

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.

Add Pocket Tuner Tool
Ships same business day
$169.95

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.

Add Pocket Tuner Tool
Add Lighter Return Spring
Ships same business day
$579.95
DR650 '96 - '25

 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.

  • TM40 Carb pre-jetted and set-up for your particular DR650
  • Custom throttle cables to work with the TM40
  • Extra jets should you need them for fine tuning
  • K&N air filter with
  • Custom ProCycle outside foam wrap
Add Pocket Tuner Tool
Ships same business day
$639.95

Allows your bike to breathe much better giving you better response and performance.

  • Breather Filter
  • ProCycle Jet Kit which includes jets, needle, extended fuel screw, drill bits and Allen bolts to replace phillips (JIS) head bowl screws and detailed installation instructions
  • Choose Twin Air, DT1, or K&N filter with ProCycle filter wrap
  • OPTION - Twin Air breather filter (replaces standard breather filter)
Choose Filters
Add Pocket Tuner Tool
Ships same business day
$119.95
DR650 '90 - '25

Designed for use with stock engines using either stock or aftermarket exhaust and air filters.

  • Provides a simple and affordable solution to carburetor tuning problems.
  • Allows you to tune your bike for increased power and smoothness while retaining fuel economy.
  • Includes a guide booklet on how to install and use your jet kit to it's full potential.
  • For a top quality installation we recommend adding an extended fuel screw and a set of replacement carburetor screws.
Add Pocket Tuner Tool
Ships same business day
$102.95
DR650 '96 - '25

The jet kit for riders who want their bike to run well but do not want to modify the air box.

The Ti ProKit w/Titanium needle adds more power and better throttle response. Easy to install and tune - no slide drilling. No air box modification.

Includes: a main jet selection, adjustable titanium needle, clips (with extras), pilot jet, instructions.

Add Pocket Tuner Tool
Ships same business day
$69.95
DR650 '96 - '25

This kit includes 2 needles that have been developed by JD Jetting and manufactured for them to their exacting specifications. These two needles allow a wide range of tuning possibilities and provide correct fuel delivery at any throttle position.

4 Allen type screws for the float bowl are also enclosed should you strip out the stock screws during your tuning process. Complete instructions with photos, jetting suggestions for different set-ups and situations, 4 Main Jets, a new Pilot Jet, and a drill bit complete the package.

Add Pocket Tuner Tool
Ships same business day
$84.95

Kit includes:

  • 155 Main Jet
  • 40 pilot jet
  • #35 leak jet
  • EMP needle

Not for the stock carburetor Fits FCR-MX conversions Only.

Add Pocket Tuner Tool
Ships same business day
$32.95

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.

Add Pocket Tuner Tool
Ships same business day
$84.95

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

Ships same business day
$79.95
DR650 '90 - '25

This is an O.E. replacement diaphragm for your BST40 carburetor.

Ships in 3-5 business days
$28.95

This Kit replaces vital components in the BST40 Carburetor including new o-rings, gaskets, jets, needle, mixture screw, float bowl screws, float valve needle and seat (needle jet and other pressed in jets are not included in kit) to return the stock Mikuni BST40 Carburetor to like-new operation. As a bonus we have included Viton o-rings for the float assembly and 4 stainless steel allen screws.

Add Pocket Tuner Tool
Ships same business day
$47.95

This Kit replaces vital components in the BST40 Carburetor including new a Float, Needle Valve, Gaskets, Seals, Diaphragm, Spring and Float Bowl Screws to return the stock Mikuni BST40 Carburetor to like-new operation. As a bonus we have included Viton o-rings for the float assembly and 4 stainless steel allen screws.

Add Pocket Tuner Tool
Ships same business day
$63.95
  • Include top cover gasket, jet needle E-ring and washer, throttle valve seal, pilot air O-ring, fuel joint O-ring, accelerator pump O-ring, needle valve O-ring, needle valve retainer screw, needle valve assembly, float bowl O-ring/gasket, overflow hose, float bowl screws, accelerator pump rod boot
  • Genuine Mikuni parts properly replace worn or mistreated components for the TM42 carburetor
  • Includes all the parts needed to rebuild TM42 carburetor
Ships in 3-5 business days
$44.95

Has your TM40 carburetor been sitting for too long and now needs to be rebuilt? Then what you need is this TM40 Rebuild Kit that contains Genuine Mikuni replacement parts.

This kit includes:

  • Needle Clip and Washer
  • Top Cover Gasket
  • A/P Nozzle O-Ring, Plug and Rubber Cap
  • Fuel Screw O-Ring, Washer and Spring
  • Float Bowl O-Ring
  • Pilot Fuel Screw
  • Drain Plug O-Ring
  • #3.8 Needle Valve Assembly
  • O-Ring for the Starter Circuit and Needle Valve
  • New Screws for the Float Bowl
  • Vent Hose
Add Pocket Tuner Tool
Ships same business day
$39.95

Softer return spring for your TM40 carburetor.

This replaces the stock return spring that comes with the TM40 carburetor creating a 25% lighter throttle feel.

Ships same business day
$12.95
DR650 '90 - '25

Replace the worn slide guide in your stock Mikuni BST carburetor before it causes additional wear to the needle and needle jet. There are wear indicators on the slide guide that help you recognize when it is time to replace your slide guide. New O-ring included. 

Add Carburetor Slide
Ships same business day
$37.95
DR650 '90 - '25

A new slide for the stock Mikuni BST carburetor.

Add Carburetor Slide Guide
Ships same business day
$47.95
DR650 '96 - '25

Is the cylinder head intake boot on your DR650 cracked or weathered, is it missing parts of the lip to seal around the carburetor, have you recently pulled the intake boot off only to realize the O-ring behind it is hard & brittle? This kit is your solution to solving some of those mystery problems and make your bike like new again. There can be a great deal of heat that can radiate behind the cylinder head on a DR650 as it is an air cooled engine. With that comes long term maintenance items that will need to be replaced due to them being made of materials that cannot withstand those constant heat cycles indefinitely.

Our kit includes O.E. parts from Suzuki to include:

  1. Intake Boot
  2. Metal Clamp
  3. Premium Japanese O-ring
Ships same business day
$44.95
Universal fit. May require additional adjustment or modification.

Genuine Keihin spring, washer, and oring for the fuel screw of FCR and FCR MX carbs.

Just the parts…
Fuel screw spring, washer, o-ring (fuel screw not included)

Ships same business day
$8.95

This cover acts as an 'adjustable leak jet' to fine tune the accelerator pump squirt.

Eliminates "4-stroke bog" when used with correct jetting. Allows the use of correct carburetor settings to optimize performance, starting and reliability. Improved low-end performance with much better throttle response. Investment cast and finished to precise tolerances with internal high volume vertical check valve. Fits all motorcycles and ATVs using a Keihin FCR carburetor Easy installation instructions (including online video) and template.

Not for the stock DR650 carburetor Fits FCR-MX conversions Only.

Ships in 3-5 business days
$119.95

Direct replacement for the stock spring and exactly like the old Merge Racing spring. Gives a much more consistent accelerator pump squirt. Eliminates the need for the 'O-ring mod', wire or zip-ties on the pump arm. Fits all Keihin FCR-MX carbs except '07-'08 CRF250/450.

Not for the stock DR650 carburetor Fits FCR-MX conversion Only

Ships same business day
$29.95

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.

Ships same business day
$24.95