Engine, Tools, $25 and Under
Engine & Maintenance
Getting ready to adjust your valves? Here is a set of feeler gauges to make the job a little easier. One tool has .002" & .003" gauges the other has .004" & .005" gauges. Yamaha lists the specs as follows: .002"-.004" Intake and .004"-.006" Exhaust, clearance measured when engine is cold.
A set of feeler gauges so you can adjust the valves on your Yamaha. Yamaha says that when the bike is cold, the Intake should be between .002" and .004" and the Exhaust should be between .006" and .007".
This set includes one gauge with a .004" on one end and a .005" on the other for your intake side and another with a .006" and .008" for the exhaust side.
Engine
Big Bore
+2mm oversize from stock.
Requires cylinder boring only. Bore Diameter: 83mm, Piston Diameter: 82.95 mm
12.5:1 compression. Includes pistons, rings, pins, clips and head gaskets.
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 (cast iron, chrome, nikasil and boron)
Wiseco’s wide range of oversize pistons increase the life of cast iron lined cylinders.
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.
High quality bore kit that shows substantial power gains throughout the RPM range. 65mm piston. 9.8:1 compression ratio allows use of premium pump gas. Complete kit includes: cylinder, piston, ring set, pin, clips and gaskets.
- All new design
- Brand new high quality BBR aluminum cylinder
- 9.8:1 compression ratio
- 65mm piston
- Includes cylinder, piston, pin, rings, and gaskets
Big bore kit for the 2003-2005 CRF150F. A simple bore in bore kit that includes BBR's high performance camshaft and valve springs for added performance. This cam features higher lift and duration than stock. Complete kit includes piston, rings, pin, clips, BBR MX cam, valve springs and gaskets. This is the quickest way to add the most power to your bike. Great when combined with our exhaust system, Rev-Box, and Free-Flow airfilter. Requires machining of stock cylinder for installation.
- Adds up to 3.5 HP
- 67mm piston, pin, clips, and rings
- 10.75:1 compression ratio
- Includes head and base gaskets
- Makes more aggressive style of power
- Bike still starts easily and idles smooth
- Same camshaft as used by the BBR Race Team
- Requires professional boring of your stock cylinder
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.
An easy big bore kit that increases your KLX110cc motor to 130cc. Includes piston, rings, pin, clips, and gaskets. A quick and inexpensive way to really improve your engine.
- 57mm aluminum piston with pin, clips, and rings
- Includes base, head, and side cover gaskets
- Requires boring of your stock cylinder
New aluminum cylinder with plated aluminum liner. High performance camshaft with lightweight piston. This is the largest bore kit available for the KLX110 that does not require boring your engine cases.
- Aluminum cylinder with plated aluminum sleeve
- BBR high-performance camshaft
- 60mm lightweight aluminum piston
- Includes gaskets
- Kit includes aluminum cylinder with nickel-carbide coating designed with larger water jackets
- Specially designed, high performance, hard anodized power valves (cannot use OEM)
- Forged piston with molybdenum coating
- Does not include cylinder head.
You will need to tune your EFI with something like the Power Commander V to get the most out of your Big Bore kit.
For riders looking for advanced performance. Kit comes with everything you need to turn your XT250 into a rocket.
- 81mm piston kit
- 11:1 compression
- Big bore sleeve
- Top end gasket kit
As with any engine or exhaust modification, you will need to re-tune your fuel delivery system for optimum performance.
ProCycle 440cc BIG BORE 89mm KIT 2 With Cam Complete kit with 11:1 Wiseco piston (with rings, pin & clips), big bore cylinder sleeve, HotCams stage 3 camshaft and top end gasket set. You will have to have the larger sleeve installed in your cylinder.
The Complete Top End Performance Kit includes:
- 102.4mm Wiseco piston 9:1 compression (up from 8.3:1) with rings, wrist pin and circlips
- Stage 1 camshaft for more power
- Top end gasket set
This kit boosts your displacement from 644cc to 675cc. Your cylinder must be bored to fit the larger piston.
Gasket
Here's another item you might want to replace when you are changing out your front sprocket. Because of it's big back tire, the chain is further away from the center of the engine than most bikes. The engineers at Yamaha decided they had better support the end of the countershaft since it is cantilevered out there so far. They also figured they had better feed some oil out there as well. These Countershaft Seals keep that oil where it belongs, lubricating the countershaft outer support.
Leaking Base Gasket? Replacing your worn Rings? Here are the gaskets you need to put your TW200 top end back together after a tear down. Includes: Head Gasket, Base Gasket, Stud Gasket, Head Side Cover O-Ring, two Valve Cover O-Rings, Base O-Ring, Stud O-Ring, Rocker Shaft O-Ring, two Cam Chain Tensioner O-Rings, Intake Manifold O-Ring, two Valve Stem Seals, and Exhaust Gasket.
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.
Here are the O-Rings you need when you perform an oil change. The largest one and the smallest one go inside the oil filter housing cover. The second largest one goes on your oil drain plug. The second smallest one goes on your oil fill plug. Replacing these O-Rings regularly will help keep your engine from seeping oil.
Oil Filter
Providing unbeatable performance and exceptional value, Hiflofiltro 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.
Grab our 5-pack and save both time and money!
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!
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 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. Flo's stainless filter catches items down to 35 microns "absolute", which is about 3 times better than most good paper or brass filters. The pleat seam is welded, able to withstand up to 600 degrees in our filter, not glued, like paper filters.
Providing unbeatable performance and exceptional value, Hiflo filtro 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.
Grab our 5-pack and save both time and money!
Africa Twin with DTC
- In addition to the main oil filter, bikes with DTC have an additional oil filter in the clutch circuit
- Constructed using the best materials available
- With the experience of more than five decades, constant research and development and featuring a completely modern production facility, Hiflofiltro offers some of the best quality filters in the world
- TUV approved and production monitored to ensure OEM or better quality
- Sold as a package of 5 filters
Spark Plug
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
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!
Eagle Manufacturing balancer lever kit, featuring top-quality components.
The Eagle Manufacturing idle-shaft lever and spring is designed to replace the less durable stock unit. The one-piece lever is precision machined from 17-4PH hardened stainless steel, ensuring exceptional strength. The kit also includes a stainless doohickey and a torsion spring with a drill bit, replacing the previous extension springs with a superior torsion spring for enhanced durability.
Our very own version of the popular thermostat bypass for the KLR. Gives faster warm up and more constant engine temperatures. Eliminates the wildly fluctuating engine temperature gauge. A more controlled and constant temperature is easier on your piston and cylinder and may prevent or reduce oil consumption. We use a 180 degree thermostat instead of the stock (too cold!) 160 degree unit. Warmer coolant temperature promotes better fuel vaporization and can increase fuel economy.
Our bypass system mounts the new thermostat in a small billet extension housing right where the stock thermostat is now. There is no bulky external housing to hang off the motor. The bypass hose tees in to the lower radiator hose using a length of quality high temperature silicone hose. It all makes for a clean simple installation.
Cam
- 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.
Designed to enhance mid-range and top-end power. Manufactured using the highest quality standards. No core required.
Note: This camshaft has been designed to work with the OEM Yamaha piston, or the BBR big bore kit piston, with OEM sized valves. Any other combination of parts will require that you manually check valve to piston clearance.
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.
Clutch
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.
- Cork-based clutch material impregnated with aluminum particles to increase wear life and heat resistance
- Highly compressed construction avoids swell and clutch drag
- Ideal for general-purpose street/sport/touring bikes
- Kit includes complete engine set of friction plates only
- For use with manufacturer's recommended drive case oil.
Designed to improve the life and durability of your clutch, Barnett's "Dirt Digger" provides better rideability with less slippage compared to stock.
- Kevlar friction plates
- Tempered steel drive plates go through a vibratory de-burring process and then are quality checked for flatness to provide optimum performance.
- Heavy duty clutch springs are pre-set, shot-peened, and heat treated for performance and durability.
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, cork-based facings for smooth clutch take-up, and allows engagement modulation, unlike paper clutches which tend to snatch.
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.
The Dirt Racer Complete Clutch Rebuild Kit is the ultimate package for your Yamaha, here's why:
'Stack Height' is the all important factor when renewing a clutch and riders are always best to buy a complete kit instead of separate single plates as sold by manufacturers. Replacing just the worn plate (or plates) may not even get close to rebuilding your clutch to its original stack height and all you get is clutch slip and the job has to be done again.
- Complete set of stack height controlled anti-swell friction plates
- The friction plates are forged allow with wide "Ear" construction to spread the load in the clutch basket and prevent "Dogging" (when the ears cut into the allow clutch basket) which causes a rough clutch, promotes slippage plus it ruins an expensive part of your engine
- EBC unique alloy article impregnated clutch facings that wear longer and resist burning
- 15% stronger heavy duty, shot peened clutch springs to clamp those plates together firm and strong for the life of your clutch
Hinson Clutch Plates available as a set of just Fiber Plates or just Steel Plates or as a complete set including both.
Hinson Clutch Components sells the best clutch components available in the world. Hinson equipped machines have won 224 National and World Championships in our 20 years of business.
- Optimum hook up with minimum heat build up provides high performance
- Developed with and recommended to enhance the performance of Hinson clutch baskets, inner hubs, and pressure plates
- Exceptional production tolerances and flatness
- All fiber plates use organic non-abrasive materials to avoid damage to rest of motor as plate materials break down and are circulated through engine by oil
- Can be used with OEM baskets, inner hubs, and pressure plate
- Cork-based clutch material impregnated with aluminum particles to increase wear life and heat resistance
- Highly compressed construction avoids swell and clutch drag
- Ideal for general-purpose street/sport/touring bikes
- Kit includes complete engine set of friction plates only
- For use with manufacturer's recommended drive case oil.
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.
Valves
Premium cylinder head upgrade.
Features CNC machined port shapes, larger high performance valve seats and custom made valves. Valve sizes are increased from the tiny stock 33mm intake & 28mm exhaust to 36mm intake & 32mm exhaust.
This is not a radical modification. These bigger valves bring the valve sizes up to what would normally be found on other brands of 650 singles.
We strongly recommend checking valve to piston clearance when installing oversized valves.
This option is ideal for those who desire the least amount of down time to install this engine upgrade.
This kit includes a core charge that allows us to ship your kit before we receive your stock cylinder head core in 'good' condition. More details regarding core exchange linked below.
Piston
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.
Raises compression from stock 9.5:1 to 10.5:1 for more power and snappier response. Highest quality Wiseco pistons are forged in the USA. Fits the standard size stock bore.
As with any engine or exhaust modification, you will need to re-tune your fuel delivery system for optimum performance.
If you're plannig to or already have a stroker crank setup in your Yamaha WR250R/X, you'll need this stroker piston.
Features:
- All piston skirts are coated with a hi-tech Molybdenum Disulphite coating for faster break-in time and increased piston life
- Cast Replica piston kits are gravity cast aluminum alloy (not forged) with 18% silicone content, which produces an extremely light but very strong piston
- Forged Replica pistons are forged from 2618 aluminum for superior strength and durability
- Forged High Compression pistons improve power and torque across entire rpm range
- Forged Big Bore pistons increase engine’s displacement, torque, and peak horsepower
- Forged Replica pistons are forged OE replacements
- All pistons are heat treated with a T-5 hardening and tempering cycle
- Replica pistons and all rings are OEM replacements
- Kits include piston, rings, wrist pin and circlips
- Two stroke replacement rings are sold individually (Example if your piston has two rings you will want to order two rings)
- Four-stroke piston rings sold as a set
Gasket, Oil Filter
Crankshaft
This is a completely rebuildable stroker crank (3mm additional stroke) turns your mild mannered 250cc motor into a 263cc trail shredding monster! OK, maybe not, but sure makes it a fun machine.
Want the COMPLETE package? Order a Big-Bore kit to go with your stroker! That will give you a 308cc ripper! That is 24% larger than the stock 250. This package includes the Athena Big Bore Kit plus the 3mm Hot Rods Stroker Crank with new Genuine Yamaha crank bearings.
You will need to tune your EFI with something like the Power Commander V to get the most out of your Stroker kit.
For stock bore Hot Rods highly recommends you use the Vertex Stroker Piston Kit.
Drain Plug
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
Engine, Tools
Engine & Maintenance
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.
Repair Manuals
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.
This Clymer Repair Manual is an essential resource for anyone looking to service or repair their motorcycle at home. Whether you're riding at the weekend or using your bike for a daily commute, you don't want your plans disrupted - performing regular maintenance is crucial to keep things running smoothly.
Every Clymer workshop manual is the result of a full stripdown and rebuild, allowing you to really know the detail behind your bike. Alongside step-by-step instructions and expert advice, you'll find a wealth of images that help to guide you through repairs and servicing tasks, even on small and complex parts.
What's Included
- Step-by-step instructions based on a full stripdown and rebuild of the bike
- Tips and techniques written by Clymer's motorcycle experts
- A time saving troubleshooting guide with common issues for your motorcycle
- Wiring diagrams for key vehicle systems
- Pictures and illustrations to make tricky jobs easier
- A printed book, dispatched from our US warehouse
(This manual's year range represents the years of coverage available when the manual was written. The vehicle or machine's production years may extend beyond these dates.)
Clutch, Engine & Maintenance
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 a breeze, and minimizes the likelihood of damaging the clutch hub.
Drivetrain, Engine
Retainer, Gasket
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.