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DR650: Drivetrain

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)

Drivetrain

Many riders choose to convert over from the stock 525 to a 520 chain. Besides being lighter and less expensive, a 520 chain is more readily available as well as having more sprocket size options.

  • Steel Sprockets
  • EK SRO6 O-Ring Chain (clip type master link)
  • Smaller 3 hole retainer
Ships same business day
$119.95

Quality steel sprockets and EK SROZ2 525 O-Ring chain. Available in gear ratio choices from - 13/42 to 15/46. EK SROZ2 525 chains come in 120 link length and may have to be cut down to fit. They also come with rivet type master links. Clip type links are available below.

  13 and 14 Tooth sprockets require a smaller retainer

Add SS C/S Sprocket Retainer
Ships same business day
$149.95
DR650 '96 - '25

This is a complete drivetrain package. All the parts you need to freshen up the most important part of your motorcycle.

  • Polyurethane Drive Cushions
  • Ball Bearing Chain Roller
  • Sprocket Bolts and Nuts
  • Lock Style Rear Axle Nut
  • EK SR06 520 O-Ring Chain
  • New front and rear 520 sprockets
Choose Gearing
Ships same business day
$184.95
DR650 '96 - '25

High Quality chain. Will need to be cut to fit your sprocket combination.

Choose Type / Length
Ships same business day
$65.95
DR650 '90 - '25

High Quality chain. Will need to be cut to fit your sprocket combination.

Lower friction and longer life. X-rings have twice the sealing ability as compared to o-rings. They do a better job of keeping the lube in the links and the dirt out. DID VX chains have a reputation for being the best chain you can buy for dual sport riding. DID VX chains come with rivet type master links.

Choose Type / Length
Ships same business day
$160.95
Universal fit. May require additional adjustment or modification.

Always carry a spare master link when out on the trail.

  Master links are not interchangeable. Be sure to check the manufacturer and series on your chain.

These do not fit the TW200 or XT250. Only for 520 os 525 chains, Please verify chain size.

Choose Pitch / Type
Add Master Link Pliers
Ships same business day
$7.95
DR650 '96 - '25

This is a RIVET style master link that fits the original OEM Suzuki chain. The original chain is marked DID 525 V8. If you need a master link for your stock chain, this is the one.
There is not a clip-style master link available.

Ships same business day
$13.95

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.

Ships same business day
$49.95
DR650 '96 - '25

The DR650 is rather hard on the cush drive rubbers. Replace these any time you feel excessive play in the sprocket carrier hub. Excessively worn dampers can cause the cush hub bearing to fail - which will ruin your sprocket carrier. Sold as a set of 6 rubber dampers.

Ships same business day
$52.95
DR650 '96 - '25

Quality steel front sprockets. Choose 525 or 520. Also available 'Wide Boss' JTF438 520 sprockets.

  All 520 sprockets require a new retainer plate, please add on if purchasing this size.

Add SS C/S Sprocket Retainer
Ships same business day
$21.95

A set of three OEM Suzuki front sprocket bolts. Thread-lock compound has already been applied for extra security.

Ships same business day
$17.95

The stock sprocket retainer will rub the chain when it is used with 13 and 14 tooth sprockets.

We have our own sprocket retainer laser cut from 13 gauge stainless steel. This retainer works with all 3-hole 13T, 14T, 15T and 16T DR650 countershaft sprockets.

Choose Option
Ships same business day
$12.95
DR650 '96 - '25

Quality steel rear sprockets. Choose 525 or 520. 41T to 50T

48 and 50 sprockets require removal or modification of your lower chain guide.

Chain Size Recommendations:

  • 110 link chain for a 42 tooth rear sprocket
  • 112 link chain for a 46 tooth sprocket
  • 120 link for the 48 and above sprockets.
  • 120 link chain will have to be cut to the proper size for the 48 and 50.

*Actual sprocket color may differ from image shown.

Ships same business day
$49.95
DR650 '90 - '25

A set of six high quality grade 10 sprocket bolts with lock nuts. Thread-lock compound has already been applied for extra security.

These bolts are flat head style, requiring a countersunk hole in the sprocket.

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

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

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
DR650 '96 - '25

The cush hub (sprocket carrier) bearing leads a tough life. This is especially true if your cush rubbers get old and soft. They can allow the chain to pull the cush hub sideways putting a twisting load on the bearing. If there's any question about the condition of your bearing replace it now with this double sealed bearing and quality seal.

Ships same business day
$14.95

This new unit from JNS will protect your cases from the damage caused by a thrown chain, and will also keep your pants, boots or foot safe from your countershaft sprocket.

The case saver portion is laser cut from 0.25" aluminum and then has the 0.19" aluminum countershaft sprocket cover welded to it and the entire unit is powder coated black.

All the mounting hardware is stainless steel with machined aluminum spacers also included.

If you have a 16t front sprocket, mounting modification may be needed to fit. Install the case saver on the bike without the top spacer and bolt. This provides a little extra wiggle room. Add the top spacer and bolt after the bottom bolts are loosely threaded.

Ships same business day
$89.95
DR650 '96 - '25

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.

Ships same business day
$39.95

B&B fired up the CNC equipment for another beauty, a Front Sprocket Case Saver. A great investment the 6mm aluminum base will protect your engine cases should your chain ever break or derail. On top of that is a 4mm piece to keep your pants and other things out of the chain as well. This replaces the stock cover over the countershaft sprocket.

If you have a 16t front sprocket, mounting modification may be needed to fit.

Choose Option
Ships same business day
$96.95

Stock chain guard crack and crumble on you? Won't happen to this unit CNC machined from 2.5mm marine grade aluminum. Polished to a beautiful sheen that will give your DR that little twinkle as well as better protection.

Choose Option
Ships same business day
$107.95

Replace your lost or broken stock plastic chain guard with a JNS aluminum one. Laser cut, CNC formed, TIG welded, and powder coated a beautiful satin black. This is a direct replacement for the stock unit.

  Please note that this unit is a bit wider than the stock one and will have to be trimmed if you are running a big fat SuperMoto wheel/tire.

Ships same business day
$59.95

A real Heavy-Duty Chain Guide manufactured from 5mm (3/16") thick 5052 Aluminum. This guide will take a pounding and continue to put that chain right on the sprocket. The rub block is machined from UHMW plastic and can be positioned to fit just about any sprocket available for the DR. These are powder coated black for a great look and additional protection.

Ships same business day
$94.95

A CNC machined chain guide for the DR. Stronger than the wimpy stock unit and can easily accommodate the stock 525 chain as well as a 46 tooth rear sprocket (by moving the lower rub block to the forward position). The rub blocks are also a higher grade, longer lasting material.

Ships same business day
$59.95

Savvy DR650 owners will remove the upper chain roller. You can use this stainless steel button head screw to plug the threaded hole. Suzuki did not make the upper roller mount strong enough. If you don't remove it yourself the chain will likely do it for you - along with a chunk of metal out of the frame.

Ships same business day
$1.95
DR650 '96 - '25

Replace your lower chain roller with this high quality roller with 2 sealed ball bearings. The stock roller has no bearings. It's just a plastic wheel riding on a bolt. Ball bearing chain rollers are smoother, quieter and last longer.

Ships same business day
$17.95
DR650 '96 - '25

The chain slider protects the swingarm from contact with the chain. Replace yours before it wears through to the swingarm.

Ships same business day
$48.95
Universal fit. May require additional adjustment or modification.
  • Accurately and quickly measures chain slack
  • Two scales measure both chain slack and chain to swingarm clearance
  • Setting chain slack properly dramatically improves chain life
  • Lightweight compact design fits easily in your tool box or road kit
  • Works on most street and dirt bike applications up to 75mm chain slack
  • Made from engineered nylon with aluminum measuring scale
  • Anodized laser-etched precision measuring scale
  • Refer to your owner's manual for proper chain slack and procedure
  • Patent pending
Ships same business day
$19.95
Universal fit. May require additional adjustment or modification.

Designed for quick and accurate alignment, this tool clamps squarely to the rear sprocket so the alignment rod can indicate sprocket alignment with the chain.

Ships same business day
$18.95
Universal fit. May require additional adjustment or modification.

Can break or rivet chains from #35 to #530 like a pro.

kit includes a 2mm, 3mm, and a 4mm pin to fit most chains.

kit includes press plates,and all necessary riveting pieces and comes in a durable plastic case.

NOTE: when breaking a chain, YOU MUST grind the heads off of both pins on a link first.

Ships same business day
$74.95
Universal fit. May require additional adjustment or modification.

Here is a tool to help you remove a few links from a chain that is too long. A great tool to have in your tool box.

The head of the pivot pin you are going to remove must be ground down level with the side plate before using this tool to push it out. Failure to do that will cause damage to the tool that is not covered by any warranty!

Ships same business day
$24.95
Universal fit. May require additional adjustment or modification.

Innovative design that cleans chain from 3 angles at once. Long handle keeps fingers and hands away from chain and sprockets.

  • Will not harm O-ring chains
  • Easily adjustable for all chain sizes
Ships in 3-5 business days
$13.95
Universal fit. May require additional adjustment or modification.
  • PBR = press, break, rivet
  • Innovative design will press, break and rivet 520, 525 and 530 chains with one convenient tool (not for use on 428 chains)
  • Versatile design will remove chain pins, press master-link plates and rivet hollow nose and soft nose (quad stake) master link pins on O-Ring and non O-Ring type chains
  • Easy-to-use design allows you to change tool functions by simply moving the position of the anvil block
  • Indexing letters on movable anvil and body ensures correct tool configuration; simply line up the letter on the anvil to the letter on the body to get the configuration you need
  • All components conveniently store on tool when not in use
  • All steel construction with heat-treated components for strength and durability
  • May be supported in a vise or held with included handle
  • Great for the professional technician or DIY mechanic
  • Compact and light enough to carry in a tool bag for trail-side repairs
  • Patent Pending
Ships same business day
$104.95
Universal fit. May require additional adjustment or modification.

Make your life a little easier by having a set of these in your toolbox. Designed to simplify installation and removal of clip-type master links. One tip is shorter and notched to be placed on the pin which allows the longer end to push the clip.

Ships same business day
$23.95
Universal fit. May require additional adjustment or modification.

This Motion Pro press tool is a must have when installing and removing Clip-Style master links (520, 525 & 530 sizes).

Easily presses on and off master link plates, works on 520, 525 & 530 Clip-Style master links.

Maximum master link width 24.8mm.

Will not damage master links, hardened steel pins for reliable use.

Light weight billet aluminum construction.

Ships same business day
$36.95
Universal fit. May require additional adjustment or modification.

A high quality master link press tool from Wirth Machine used for the removal and installation of master links using a press fit link plate.

Fits 520, 525, and 530 pitch chain.

Ships same business day
$36.95
Universal fit. May require additional adjustment or modification.

ULTIMATE SPROCKET WRENCH KIT

  • 12” long wrench gives you more torque to get those thread locked sprocket bolts off easily
  • Double ended 12mm & 13mm to fit all modern motocross, Enduro and dual sport bikes
  • Dog leg wrench design allows wrench to easily clear rim edge and wide tires
  • 8mm allen fits most Japanese bikes 8” long for extra leverage
  • Torx T45 fits late model KTM and Husqvarna bikes, 8” long for extra leverage
  • Vinyl coated handles to protect rim edge and give a non slip grip
  • Makes routine sprocket bolt maintenance a quick and easy job
Ships same business day
$19.95