DR650: 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.

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.

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.

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.

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.

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.

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.

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.

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.

• 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.

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.

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.

A set of four high quality valve stem seals.

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.

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

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!

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.

• 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.

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

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.

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

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

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

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.

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.

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.

DP Premium Clutch Kit is engineered to provide superior performance compared to any original equipment manufacturer (OEM) or aftermarket clutch. DPK kits come equipped with friction plates, steel drive plates, and clutch springs, with the exception of those OEM clutches that feature a reusable diaphragm spring.

Each clutch kit is packaged in a foam-lined hard plastic case, ensuring protection of the components prior to installation. This case can also be utilized for the storage and transportation of parts, tools, or other items after the clutch has been installed. The kits are delivered ready for racing, eliminating the need to pre-soak plates in oil.

Designed to promote ultra-smooth power delivery, these kits incorporate exclusive high-heat friction materials that ensure fade-free performance. The friction compounds are specifically formulated for optimal performance in off-road and dual-sport motorcycles, and they are more durable than OEM plates. The steel drive plates are designed not to expand, fade, or contribute to clutch swell, as can occur with stock aluminum plates, and offer an extended lifespan ranging up to 300% more than standard plates.

The increased weight of the steel plates enhances the flywheel effect, aiding in starting and traction without muddying or contaminating the oil.

These clutch springs are precision-wound utilizing high-quality chrome silicone wire. They are heat-treated and shot-peened to maximize longevity, with each spring meticulously designed to prevent slippage while providing robust spring rates that improve the feel and ease of clutch operation. 

Remember to use a new clutch cover gasket during installation.
 

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.

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.

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.

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.

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.

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.

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.

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.

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

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

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

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.

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

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.

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.

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
• 5-Pack of Oil Filters
• Magnetic Drain Plug
• O-Ring Kit
• Air Filter
• Spark Plugs

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.

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.

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.

• Cleanable and reusable filter
• 35 micron stainless steel mesh
• Stainless check ball and stainless spring
• CNC aluminum caps front and rear

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 $3.79 per filter with our value 5-pack!

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

GoldPlug is the gold standard in engine protection.

Stainless steel drain plug with an extremely strong magnet that picks up metal flakes in your oil.

14mm Thread

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.

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.

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

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.

• Use with 3/8" drive ratchet or wrench
• Choose the one that fits your spark plug size:  14mm, 16mm, 18mm, or 21mm.

E3 Resistor Spark Plugs

The unique design of the electrode maximizes the power generated by the spark plug through Diamond Fire technology. This electrode combines advanced performance capabilities and innovative technology to enhance the shape of the flame kernel. Consequently, the flame front ignites the air/fuel mixture more rapidly, accelerates heat transfer into the combustion chamber, and creates a more concentrated pressure front, facilitating a quicker pressure rise during the cylinder power stroke. The outcome is a more efficient combustion process and improved engine performance, making this a truly premium spark plug.

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

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.

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.

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.

• 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

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.

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.

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.

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

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.

A 3-pack of easy to apply strips measure the temperature of engine, suspension, and radiator components. Temperature range 149° to 248°

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.

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.

• 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

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.)

12-Blade Angled Combination Tappet Feeler Gauge Set 

• 4" long angled blades, hardened and polished
• Manufacturer's lifetime warranty
• Dual marked 0.203mm-0.660mm and 0.008"-0.026"

32-Blade Dual-Reading Tapered Combination Feeler Gauge Set

• 95mm (3.75") long taper blades hardened and polished
• Manufacturer's lifetime warranty
• Dual marked: 0.03-1.00mm and .0012-.040 in.