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DR650: Fuel and Intake

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)

 

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
$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 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
$579.95

The Mikuni TM42-6 HSR flows 17CFM more than the TM40-6 and incorporates many upgraded features such as a roller-bearing slide.

All this means going even faster has never been so easy, say goodbye to hard starting, hesitations and flat spots. 

These Mikuni carburetors are correctly sized and easily fitted to your Suzuki DR650 stock air box when using the silver anodized air-box adapter. This adapter is fitted prior to delivery when purchasing complete kits, includes provisions to install your existing choke cable.

Add Pocket Tuner Tool
$689.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. ProCycle Approved

Intake Kit, Complete

DR650 '96 - '23

 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
$639.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. ProCycle Approved

Intake Breathe Easy Kit

DR650 '96 - '23

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
$119.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Jet Kit, DynoJet

DR650 '90 - '23

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
$89.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Jet Kit, Factory Pro

DR650 '96 - '23

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
$69.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Jet Kit, JD Jetting

DR650 '96 - '23

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
$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
$32.95

Kit includes:

  • Main jets: 145, 150, 155 and 160
  • Pilot jets: 38, 40 and 42
  • Merge Racing AP spring
  • JD Fuel screw
  • #35 leak jet
  • EMP and EMR needles


Everything you need to dial in your FCR/DR650 conversion. Enough jetting to cover most modifications or altitudes.

 Not for the stock carburetor Fits FCR-MX conversions Only

Add Pocket Tuner Tool
$119.95

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
$84.95

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
$47.95

FCR-MX Carburetor Rebuild Kit

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

Add Pocket Tuner Tool
$45.95

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
$63.95

Has your TM 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
$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.

$12.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Carburetor Slide Guide, BST

DR650 '90 - '23

Replace the worn slide guide in your stock Mikuni BST carburetor before it causes additional wear to the needle and needle jet.

Add Carburetor Slide
$37.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Carburetor Slide, BST

DR650 '90 - '23

A new slide for the stock Mikuni BST carburetor.

Add Carburetor Slide Guide
$47.95

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.

$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

$14.95

If you are converting a Keihin FCR-MX 39 to fit on your DR, you need to start here. This 6061 T6 aluminum adapter bonds to the airbox side of the carb so it will easily fit the DR.

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

$33.95

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.
 

$24.95

Top quality brass screw with molded knob for easy adjustments.

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

$23.95

R&D introduces "Flex-Jet", a simple, effective flexible shaft design. Quick adjustments are now within easy reach. Besides easy access, another benefit is the Flex-Jet's ability to hold its setting. Loose fuel screws are now a thing of the past. Kit includes: Flex-Jet (Remote Fuel Screw), bracket, screw, spring, washer, O-ring and instructions.

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

$39.95

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.

$48.95

Extended float bowl screws from Wirth Machine for your OEM BST carburetor that use 5/6" or 8mm size wrench to loosen. Allowing easy access to your jets and float without having to remove the carburetor from the bike. Sold in a 2 pack. Stainless steel threads.

$9.95

Extended float bowl screws from Wirth Machine for your TM40 that use 1/4" size wrench to loosen. Allowing easy access to your jets and float without having to remove the carburetor from the bike. Sold in a 4 pack. Stainless steel threads.

$15.95

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.

$4.95

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.
 

$4.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Choke Cable Fitting, Billet

DR650 '90 - '23

The plastic fitting that secures the stock choke cable to the carburetor is delicate and easily broken. A broken fitting can cause hard to solve idling and running problems. CNC machined from billet aluminum and anodized blue or black. If you want to retain your handlebar mounted choke this may be the solution.

  These no longer fit the new version of the ProCycle Remote Choke Cable.

Choose Color
$19.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Made in USA

Choke Cable, Remote

DR650 '96 - '23

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.

$45.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Choke Knob

DR650 '90 - '23

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.

Choose Length
$17.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air Filter Cage Kit, OEM

DR650 '96 - '23

Have you lost or broken the stock air filter cage for your DR? Maybe you need a spare? Here it is, the OEM cage that will fit any of the foam air filters on this page. This kit includes the plastic holder that keeps the cage in place and the screw for that as well.

$29.95

A ProCycle exclusive. This is our favorite air filter for the DR650. Made just for us by the folks at DT1.

  • Unique triple stage foam filter designed for the most extreme conditions
  • Increased protection against silt, water, and sand
  • Allows for extended filter service intervals
  • Neoprene base gives superior sealing to air box
  • Includes resealable bag for easy oiling and storage

NoToil cleaner NOT recommended with this filter, May cause delamination.

$29.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air Filter, Foam Wrap

DR650 '96 - '23

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.

$19.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air Filter, K&N

DR650 '96 - '23
  • Increased air flow over the stock air filter.
  • Designed to increase horsepower and throttle response.
  • Easily fits inside the factory air box.
  • Larger surface area over foam filters which offers longer service intervals in dusty conditions.
  • Four layers of premium cotton gauze provides outstanding filtration.
  • Washable & re-usable, never wears out.
  • One filter will last the lifetime of your bike.

Temporarily out of stock.  Estimated to receive from manufacturer in May 2022, pending manufacturer availability.  Ordering now will reserve yours.

Add Foam Wrap
Add Pre-Filter
Add Air Filter Care Kit
$79.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air Filter, K&N

DR650 '90 - '95
  • Increased air flow over the stock air filter.
  • Designed to increase horsepower and throttle response.
  • Washable & re-usable, never wears out.
  • One filter will last the lifetime of your bike.
Add Air Filter Care Kit
$78.95

Wraps around your K&N filter to keep water and small particles out of the filter itself. K&N DryChargers are manufactured from a durable polyester material and are pre-treated with a proprietary hydrophobic process designed to prevent splashes of water or mud from saturating your K&N air filter. The DryCharger will also stop small dirt particles; yet add little restriction to the airflow of the filter. The DryCharger can be installed under the Foam Wrap.

 Pre-filter only, K&N air filter sold separate.

$64.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Made in USA

Air Filter, No Toil

DR650 '96 - '23

Dual stage foam: 2 different pore sizes create more trapping area for even the smallest dust particles. Flame laminated foam: Both "Stages" are not glued but heat sealed to provide maximum air flow. Light color foam makes it easier to see where the filter oil has covered and where it has not.

No Toil Care Kit
$30.95

The OEM vent foam filter can deteriorate after only a couple of years. When it does it can allow enough dirt into the engine to do significant damage. Replace your filter now with a washable cotton & steel screen filter.

 This filter is recommended to be oiled like any other air filter to work properly.  Its only for bikes with the stock BST40 carburetor!

$18.95

The OEM foam secondary filter can deteriorate rather quickly. Once that happens, it can allow enough dirt into the engine to do significant damage. Replace your filter now with a high-quality foam filter from industry leader Twin Air.
 

This filter needs to be oiled like any air filter to work properly. Its only for bikes with the stock BST40 carburetor!

$25.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air Filter, Twin Air

DR650 '96 - '23

Twin Air's high quality materials and superior construction deliver unbeatable performance and protection. The hands-down choice of more World and National Champions than all other filters combined.

Twin Air's fused layers of open-pore foam and fine inner foam trap even the smallest particles-without restricting airflow.

$35.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air-box Cover Hardware

DR650 '96 - '23

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.

$8.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Air-Box Filtered Vents

Universal fit. May require additional adjustment or modification.

Sold in 6 packs

  • Compatible with many air filter boxes.
  • More air flow allows you to add more fuel to your intake mixture, increasing performance.
  • 1" Diameter
$14.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Carburetor Overflow Canister

Universal fit. May require additional adjustment or modification.

This canister by Pro Circuit allows you to move the overflow tubes from the carburetor up and out of the way. Universal application.

$39.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Clamps, Nylon Ratchet Style

Universal fit. May require additional adjustment or modification.

Quick release one-piece clamps that saves space. These are great for fuel lines, controlling wires, and can be used many times.

Comes with 4 each of 8mm, 9mm 10mm, and 12mm.

No special tools needed, from Helix Racing.

$9.95