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Genuine Suzuki Factory Service Manual for the DR200.

Genuine Honda Factory Service Manual specifically for your CRF250L

A stock replacement brake pedal for the DR650. Nothing fancy but sure gets the job done. Just order it up and get back on the trail. See our Brake Pedal Adjuster Bracket that allows you to adjust the position of your brake pedal to perfection.

- Pivot CP clutch and brake lever set for Trail models.
- Lever folds outward to prevent breakage in the event of a crash.
- Lever adapter is ultra precise CNC machined out of high grade aluminum for super light weight design.

A set of replacement brake and clutch levers. Standard length.

Replacement shift lever from IMS with folding tip.

Warp 9 has created a beautiful brake pedal machined from billet aluminum to an 8mm thick work of art. A stainless steel pin eliminates wear in the frame. This pedal has the ability to move the spring loaded brake tip 10mm either way from the center position. The arm is arched to provide clearance for riders who have the lowpeg + centerstand combination.

Say goodbye to the frustration of fidgety handguard expansion plugs with Warp 9's innovative Tapped Handlebars. 

These handlebars feature ends that are plugged and tapped with an M8x1.25 threaded insert, providing a secure and reliable mounting point for all aftermarket wrap-around handguards. 

No more worrying about plugs pulling out or spinning during crashes; their robust design ensures you're good to go, even when you encounter obstacles. 

Not using handguards? No problem they've got you covered!Each set of handlebars comes with aluminum grip guards and stainless bolts, offering protection for your grips and delicate throttle tube in case of a get-off. 

Designed with an oversized 1-1/8 inch (28.6mm) clamping diameter that tapers down to 7/8 inch (22.2mm) to accommodate standard controls. Crafted from 7010 T6 aluminum tubing and featuring computer-extruded variable wall thickness, they effectively reduce vibration while enhancing overall performance and comfort. 

Note: Does not include pictured bar mounts.

• Fit models with a 1 1/8" stem clamp and a 1 1/8" handlebar
• Handlebar clamps can be pivoted to desired fore and aft location to achieve ideal riding position
• Engineered and tested for maximum strength and durability
• CNC-machined from billet 6061-T6 aluminum, then anodized for long-lasting good looks
• 2" center to center rise above stock position

Chain slippers undergo degradation over time due to friction associated with the chain's movement. To maintain optimal operational performance, it is advised to replace worn components with authentic Honda parts.

Quality steel front sprockets. Choose 13T through 15T. The stock size for the XRL is 15T. Go down in tooth count for faster acceleration.

High quality steel front sprocket

For reference, the stock gearing for the WR250R is 13/43 while the X model runs 13/42 stock gearing.

Replace these any time you feel excessive play in the sprocket hub.

Excessively worn dampers can cause the cush hub bearing to fail - which will ruin your sprocket carrier.

Sold as a full set.

Replacement rubber boot for choke knob assembly.

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

Included in this kit are the parts needed to repair a second generation TK carburetor. You get a new float bowl gasket, needle valve with O-ring, needle, mixture screw, and stock jets for the '01-'21 models kits.

Repair leaking carburetor or worn out float needle assembly.

• Kit contains all necessary gaskets, O-rings, float valve and jets
• Supplied by the same supplier the OEMs use
• Complete kit to rebuild OEM carburetor

The Phillips screws in Japanese motorcycles are not really Phillips screws. They are actually Japanese Industrial Standard (JIS) screws that are very easy to strip with Phillips head drivers.

Rebuild your crusty carburetor with parts from the same manufacturer the OEM companies use. Included in the kit are all necessary gaskets, O-rings, float valve and jets you need to rebuild your carburetor to like new condition.

FunnelWeb ProLine Filter Highlights:

• Optimum air flow for increased riding time
• Improved engine protection
• Extended filter change intervals
• Simple to install, clean and re-oil
• Easy fitment

Like all FunnelWeb filters, the ProLine Filter features profile cut, single layer, single density foam that doubles the external surface area of the filter without increasing the original filter size. The ProLine Filter traps dirt, dust, sand and mud over a larger area on its outer surface, ensuring optimal air flow is maintained for maximized engine performance and reliability.

The single layer, single density polyurethane foam has the added advantage of being easy to clean and the ability to maintain its original shape after numerous washes. Overall, compared with conventional foam filters, FunnelWeb offers more protection from dirt ingestion, has longer service intervals and maintains high airflow rates when dirty.

• Designed to fit in the factory air box exactly like original filter
• The best selling replacement air filter for competition motorcycles and ATVs
• Unique two stage design allows for easy and complete cleaning
• Dual layer of foam, can be serviced separately
• Thin Ultra Seal base is virtually impossible to tear and has a built-in "Grease Groove"

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

• Designed to fit in the factory air box exactly like original filter
• The best selling replacement air filter for competition motorcycles and ATVs
• Unique two stage design allows for easy and complete cleaning
• Dual layer of foam, can be serviced separately
• Thin Ultra Seal base is virtually impossible to tear and has a built-in "Grease Groove"

Genuine Honda replacement air filter.

These Mikuni carburetors are correctly sized and easily fitted to your Honda XR600 and XR650L stock motor mounting flange after removing the locator tags and also match the air box when using the silver anodized air-box adapter. This adapter is fitted prior to delivery when purchasing complete kits. For this Mikuni carburetor to operate correctly the motorcycles air box must be opened up to allow more air flow in. Using a hole saw, a 45mm diameter hole will be sufficient for a Suzuki DR650 but some Honda’s require way more. The best process is to keep opening up the air-box until no more improvement is noticed and you will be surprised at the difference. The kit also comes with throttle cables and a 1/4 turn quick action throttle which must be lubed before fitment. The carb comes with a couple of  Honda specific adjustments made and pre jetted for your engine. A specially made size 30 pump nozzle is fitted as the accelerator pump circuit on TM42 carbs will not work properly on Honda’s or Kawasaki’s without it.

Climate, altitude and fuel density from different octane fuels all have varying effects on final fine tuning as does cam, exhaust and cylinder head porting etc. For this reason, we have included what we have found to be a range of jets to allow you to tune to most variables.

This carb fits with most aftermarket large capacity tanks.  Some larger capacity tanks do not allow the fitment of this carb without modification. A competent person can easily heat and depress the contact area around the throttle mechanism allowing for clearance on problem tanks. Polyethylene tanks start their life as lump of poly that when melted evenly spreads itself around a rotating mold, to later carefully heat with a heat gun any section of a tank and change the shape has no effect on the integrity of the poly itself unless pushed too far, thinning it. We recommend having this professionally done for the reason some people may neglect to properly remove all the fuel from an existing tank or if not competent may make a mess of it. 

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.

Here is the little switch that mounts inside your brake or clutch lever perch and controls the brake light or clutch safety circuit. This switch often gets damaged in an unplanned dismount (aka: crash) or the plastic simply cracks from age. When this happens, you can find yourself chasing a short circuit that keeps blowing your fuse every time the brakes are applied. If this has happened to your TW, here's the fix!

Motocross brake rotor featuring ultra lightweight radically profiled contours for great looks, great self cleaning and brake performance. Made with tough and durable heat treated stainless steel. Heat treated to perfection and then diamond ground to micron accurate surface finish and parallelism and will deliver great brakes that perform well and last.

EBC rear replacement brake rotor. High friction billet steel.

Stock size rear brake rotor laser-cut from high-carbon content 410 stainless steel, then lap cross hatched and heat-treated. Each one then has a high-temp paint applied to surfaces like cooling holes and edges for a clean finished look.

Includes a fresh set of brake rotor bolts.

Warp 9 320mm Supermoto front brake rotor kit. Newly updated and stronger.

Adds serious stopping power to the DR. Included is a new rotor floating on a central mounting carrier along with a caliper relocation bracket.

Available add on options include a Galfer braided stainless steel brake line, and 12oz bottle of Bel-Ray DOT4 brake fluid.

Includes a fresh set of brake rotor bolts.

Sport Carbon pads:  

• Carbon graphite "X" pads blended with Aramid for leisure/sport use
• Low heat generation
• Best for fast, dry riding; not for mud, water, or sand
• Offroad, Semi-sintered metal

Sintered Pads: 

• The perfect brake pads for leisure use
• Offer maximum durability and excellent braking performance
• Constructed of U.S.-made sintered bronze for longest lifetime
• Best for riding in water, mud, dust, or sand

Race Sintered:

• High performance race pad with superb durability similar to that of the sintered pad.
• Higher friction level and fade resistance
• Diamond ground surface finish to speed bed-in
• Comes with new pad pins
• Race Sintered are designed for racing use only; not for street use

Includes front and rear brake pads

• Sintered Pads are best for regular riding. Long life, and good performance in all conditions
• Sport Carbon pads are made for fast riding in dry conditions. Not recommended for mud, water, or sand
• Race Sintered are designed for racing use only; not for street use

Includes front and rear brake pads.

• Sintered Pads are best for regular riding. Long life, and good performance in all conditions
• Sport Carbon pads are made for fast riding in dry conditions. Not recommended for mud, water, or sand
• Race Sintered pads are high performance race pad with superb durability similar to that of the sintered pad. Higher friction level and fade resistance. Diamond ground surface finish to speed bed-in. Comes with new pad pins. Race Sintered are designed for racing use only; not for street use

Galfer Steel Braided lines have a Teflon tube core and are wrapped with a stainless steel wire braided exterior that prevents expansion under pressure.

The benefit is a firmer brake lever with better feel because the energy that was going into expanding the stock lines now goes straight to the brake pads.

• Significantly improves response and feel over factory rubber lines
• Largest performance improvement for your money over any other braking upgrade
• Stainless steel hose resists abrasion and puncture
• Teflon core does not degrade over time like rubber lines
• PTFE Dupont 64 Teflon® hose
• Feature a heavy-duty stiffener sleeve and route just like the factory lines
• Proprietary, premium fittings
• Banjos utilizes a unique machined channel and sealing surface for leak-free installations
• R&D and engineered in the USA
• GBrakes USA controls the manufacturing process, ensuring the highest level of quality control

Each kit includes all necessary rubber components and brake pins.

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

A high quality top end gasket set for the XR650L

The complete Thermo Control package - Our in-house designed Thermostat Bypass kit, a set of Custom Silicone Hoses and a Hi-Pressure Radiator Cap. All combined to help your KLR cooling system be at the top of its game. The Thermostat Bypass kit includes a thermostat with a higher temperature rating that will keep the motor more in its happy spot.

The Silicone hoses are stronger than the stock rubber units and will better resist cracking and leaking.

• Includes aluminum cylinder, piston kit, and special gasket set designed for larger water jackets
• Bolts on with no machining required
• 94mm big bore piston
• Aluminum cylinder designed with wider water jackets for better cooling.
• Forged hi-compression piston  12.8:1
• Includes all necessary Rings, Clips, and Gaskets.

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.

Cycle Racks Bag Supports can used for many different Cycle Racks and can be used on either the front or rear rack.

When they developed these, they wanted a functional, yet "Easy On- Easy Off application. The pig tail hook goes up, over and underneath the bar of the rack, they can also be used upside down on the rear rack as side boards. To install them, wing them out, slide them in place and then wing them back down. Simply reverse the process to remove them.

Rok-Straps are supplied to secure them in place. They are pre-drilled to accept the pattern of the Roto-Pax Pack Mount (sold separately) so you can carry fuel or attach them to your own bags.

They are sold together in a set of one right support and one left support.

COLOR: Black

Their rear racks are great for adding the extra storage needed for your next adventure. They are the perfect size for a backpack or small duffel bag. Their steel racks are built to handle any riding style you throw at them, now Rotopax ready! This is the ENDURO Series DRZ400S/KLX400S rear rack which measures 10 inches wide and 12 inches long.

Easy to Install

• Great for carrying cargo, duffel bags/backpacks, and mounting Pelican, Seahorse, or any other hard cases. Givi compatible.
• Holes are in place to accept Rotopax mount with no drilling required.
• Stainless steel mounting hardware and instructions included.
• Fabricated with mild steel, MIG welded, and finished with a semi gloss black industrial grade powder coat.
• Weighs 3 lbs, 10 inches wide, 12 inches long.
• Works with stock tool bag. You can remove the seat with no interference from the luggage rack.
• Rear rack only, no Rotopax mount or side racks included.

Lowers the rear suspension. Precision machined from billet aluminum and anodized.

*Important when lowering the rear suspension you want to raise the fork tubes in the clamps an equal amount of inches that the rear is being lowered. That way your bike will sit level when done.

Disclaimer: Lowering the front and/or rear of your motorcycle will change the geometry and may affect the handling, use caution after making changes/adjustments.

Billet aluminum lowering links. Lowers the rear suspension approximately 1 to 2 inches depending on application.

*Important when lowering the rear suspension you want to raise the fork tubes in the clamps an equal amount of inches that the rear is being lowered. That way your bike will sit level when done.

Note: We only recommend the 2" lowering links for lighter non-aggressive riders as they allow the tire to rub when near bottoming.

Disclaimer: Lowering the front and/or rear of your motorcycle will change the geometry and may affect the handling, use caution after making changes/adjustments.

• Seal profile is engineered to create equal pressure in each seal lip; equalized seal pressure creates less drag and longer seal life
• Patented MAX-LIFE has a coefficient of friction up to 3 times less than the OEM seal material
• Triple-lip seal design
• Dyno-tested to last 3 to 4 times longer than OEM seals
• Directional ribs allow seal to be installed easily
• Kit includes fork seals and dust wipers
  
   

Both kits include all bushings, snap rings, and washers.

Gen 2 kit also includes the necessary O-rings.

Gen 1 kits are OEM bushings, snap rings and washers.

• Lighter and stiffer than stock, these high quality straight rate springs are made specifically for the DL line.
• A proper rear spring will give a smoother more controlled ride.
• Available in a multitude of spring rates, one is the perfect fit for your bike and riding style.
• Stock spring is rated at 8.2 kg/mm for the DL650, and DL1000

 Adapters are required for this spring

Race Tech HP Springs have a high stiffness-to-mass ratio. In other words; the springs are light weight for their particular spring rate. This requires the finest materials and processing. Shot-peened and pre-set so they cannot sack out. All Race Tech HP Springs have the highest rate tolerances in the industry. These are the finest springs in the world-guaranteed.

OEM spring rate is 6.7kg/mm. We offer stiffer spring rates for riders who wish to carry luggage or just prefer firmer suspension.

Race Tech shock springs require adapter collars which are included with your spring. *Spring color may vary due to specification requirement and availability.

The correct spring rate for your weight will give a smoother more controlled ride. No more bottoming out, and improved traction and confidence off-road.
8.6 & 9.6 springs require an adapter which is included.

Recommended rates:

• Rider & gear up to 150 lb = Stock 6.5 spring
• Rider & gear up to 200 lb = 7.5 spring
• Rider & gear 200-275 lb = 8.3 spring
• Rider & gear 275-350 lb = 8.6 spring
• Rider & gear 350 lb & up = 9.6 spring

*Spring color may vary due to specification requirement and availability.

Charges and maintains all 12 volt lead acid, gel and lithium iron phosphate (LiFePO4)/lithium ion polymer Non-RS/Non-BMS powersport batteries

Features:

• CONSTANT CURRENT CHARGE - If the battery voltage is over 10 volts, the charger will deliver a 2 amp charge until the battery reaches 14.2 volts.
• MAINTENANCE CHARGE - When the battery reaches 14.2 volts, the charger will automatically convert to maintenance mode. The charger will revert to charge mode when the voltage drops below a specified voltage.
• LOW VOLTAGE RECOVERY - If battery voltage is below 8 volts, the charger will apply a .2 amp charge to recover the battery, once the battery reaches 8 volts, the charger will apply a .5 amp charge, at 10 volts a full 2 amp charge is applied until the battery is fully charged.
• AUTOMATIC VERIFICATION STAGE - Charger automatically stops charging if the battery does not reach at least 10 volts after 2 hours of charging.
• SAFETY - Power is not passed thru the charging leads unless they are connected to a battery.
• LED indicator light shows charging status.
• Includes heavy duty clamps and fused ring terminal SAE adapter.

Installs on any bike. Key operated power & kill switch. Turns on power (Lights, etc) when key is turned to 'ON'. Disables ignition system and turns off power when key is turned to 'OFF'. Two separate pairs of wires for kill switch and bike power. Includes stainless steel mounting bracket perfect for handlebar clamp.

• Compact, adhesive back
• Easy-to-read display
• Flashing low voltage warning
• Measures 1.57" diameter x .43" D
• Effective temperature range: 14 ~ 140 °F

The Trail Tech Vapor Speedometer/Tachometer units are custom designed for an exact fit. They feature a bright white backlit LCD display, waterproof connections, and all parts needed for a complete installation. These units accept AC and DC power input, and automatically switch to internal power if external power is removed. Power connectors are included. Permanent solid-state memory guarantees that data is never lost, even without power. Units are available in black.

Trail Tech provides a one year warranty and unlimited free phone and email support.

Unit functions:

• Speedometer
  • Current Speed
  • Maximum Speed
  • Selectable MPH/KMH Display
• Tachometer
  • Real-Time RPM Bar Graph
  • Numeric RPM Readout
  • Dual Programmable Shift Lights
  • Up to 20,000 RPM
• Temperature
  • Ambient Temperature
  • Engine Temperature (liquid cooled only, optional air cooled sensors available)
  • Dual Programmable Temp Lights 
• Distance
  • Adjustable Distance
  • Permanent Odometer
  • Selectable Mile/Kilometer Display
• Clock
  • Hour Meter, Stop Watch, Ride Time
  • Accumulated Ride Time
  • Permanent Hour Meter

The Shorai LFM Duration Recommendation is the best overall pick for most applications, and has been selected to give strong cranking performance and long lifespan. 

• Capable of holding a charge for up to one year without maintenance
• Two to four times the life of lead-acid batteries
• A Battery Management System that protects the battery from over-discharge.
• Carbon Fiber Composite case
• Stronger cranking for better starts
• Environmentally friendly, just discharge and dispose
• Ultra light and compact

Measures 4.45" x 3.5" x 2.28"
Weight (lbs): 1.52 lbs
Weight (kg): 0.69 kg
Cold Cranking Amps: 210
Polarity: [- +]

Each Shorai battery includes self-adhesive foam panels to achieve a snug fit in your battery box.

Dual Sport tube-type tires for the TW200 or the VanVan.

With its versatile tread pattern, the 428 makes an ideal OEM replacement.

• DOT approved
• 4 ply rated nylon carcass

Front tire is a 130/80-18 (66P load / speed rating) while the rear is a 180/80-14 (78P load / speed rating).

From Michelin. An innovative tread pattern with blocks and curved grooves, based on the Dakar-winning Desert Race tire, provides real off-road performance especially in soft terrain and challenging conditions. Specially designed compound gives a long tread life for extended adventure rides. Front and rear tire casing design ensures excellent on-road stability.

An -R after the size indicates that these are Radial tires.

These tires are R-rated (max speed of 106 mph)

Heidenau tires are made in Germany and they are high quality motorcycle tires for street, off road and adventure riding.

Durability, It’s about the Rubber

Heidenau’s compound uses a high natural rubber content, and there’s a lot on there. This naturally resilient compound, combined with sturdy Belted construction, makes for one of the most trusted, longest lasting tires available to long distance travelers.

K60 Tread design:

The K60’s interrupted block chevron pattern makes for a respectable off road tire that’s smooth on the street.

Tractionator Dual Venture from MOTOZ. Based on the popular Tractionator Adventure and Tractionator RallZ front tires, but not directional!

• Off-Road performance with great on-road manners. ( 70% dirt / 30% street )
• Proven construction and compound for adventure and dual-sport use.
• Designed in Australia for dependable performance in a wide variety of conditions without the need to change tire pressure between off-road and on-road.
• Hybrid compound with Silica for optimum grip in mud, snow, and rain.
• Reversible for extended use.

NOTE: Tubes can be run in Tubeless tires, but a Tube Type tire cannot be run Tubeless.

Heidenau tires are made in Germany and they are high quality motorcycle tires for street, off road and adventure riding.

A tire worthy of standing side by side with the legendary K60 Scout. The K60 Ranger is designed and developed to be the off-road cousin in the K60 family. This is not a Scout with different tread. Heidenau started from scratch with entirely new carcass and compound to maximize off-road performance and reliability.

“Rated by Heidenau as a 30% street / 70% off-road tire, the new K60 Ranger sits next to the K60 Scout in Heidenau’s lineup, offering a more off-road biased design to help adventure riders explore further into the backwoods with more confidence to tackle difficult terrain. Like the Scout, the K60 Ranger also gets a reinforced carcass with high puncture resistance. Where it differs is a more-open, knobby tread pattern that utilizes large gaps between center blocks, instead of a continuous center strip, giving it the ability to dig into loose terrain more effectively. What’s more, the Ranger utilizes a softer rubber compound that helps increase grip both off-road and on the street. Plus alternating side lugs, tied together with crossbars, enhance the tires ability to climb out of ruts and improve cornering stability.” – Rob Dabney - ADV Pulse

Tread design:

The K60 Ranger’s new tread design has dirt and big bikes in mind. While the open block design should keep the tread from loading-up in muddy conditions, the compound and carcass should keep the ride stable when you’re back on the street. With features intended to give integrity to the side blocks, the K60 Ranger should be at home on single track or cruising down the highway.

Tubeless tires (TL) can be used with spoke wheels, but Tube Type (TT) tires cannot be used with TL wheels.

This is a great SuperMoto tire that has increased grip on wet roads, with a focus on low friction surfaces (such as city streets, worn tarmac, etc).

These have a compound solution that enhances chemical grip and adhesive properties in all different situations.
Metzeler's patented mixing process delivers a more homogeneous compound that emphasizes the chemical properties and results in more resistant to the wear process.

These are tubeless tires and V rated (max speed of 149 mph)

Reusable billet aluminum muffler joint gasket. Factory joint gaskets usually cannot be removed from the pipe without damage. This one can be used over and over again. Pays for itself the first time you need to remove you muffler during service or repairs.

This is a new gasket for the cylinder head - head pipe junction. Installing a new one with your new header will ensure a good seal and no exhaust leak.

Bradley performance bomb header for TW200. 

By positioning this “Bomb” at a key point in the system, increased performance and flow is achieved through the expansion and contraction of exhaust sonics through the system. The result is a flow increase of nearly 10%. 

The outer chamber in the Powerbomb allows the air to expand, cool and ramp back up at a higher velocity. 

Fits all years of TW200 and works with all other brands of mufflers. Stainless steel and nickel plated. A clamp-on shield can be added, sold separately.

Their baffle was designed to replace the stock insert. The baffle produces a nice note compared to the de-restricted stock version and dyno test results showed an increase on 2 hp up top.

A noise test on the insert was conducted at the EPA Victoria Vehicle Test Station at Macleod under controlled conditions with Class 1 meters.

Some extra details:

1. The ADR test is conducted at an engine speed which is 50% of the engine rpm at which the engine develops maximum power. However, this engine speed is determined when the bike is in restricted form, with a throttle restrictor that stops the throttle being fully opened. This is why the ADR engine test speeds are so low. However, they are the engine speeds used to determine compliance.
2. On the ADR test, the B&B tip was over the signature noise emission, but a tolerance of 5 dB(A) is allowed before prosecution would be initiated. With this tolerance, the insert would not be prosecuted as it is just 4 dB(A) over the signature.
3. When tested with the standard OEM tips (as fitted when delivered from Suzuki Australia), the Suzuki came in at 95 dB(A) for the ADR test

Does not contain a spark arrestor. Check local laws on spark arrestors before purchase.

The race-bred RS-2 exhaust has proven to be extremely popular among rider looks for a combination of performance and value. It enhances performance dramatically, provides an enviable exhaust note and offers the unmistakable look and sound of Yoshimura. RS-2 mufflers feature a straight baffle that leads to a single turn-down machined aluminum end cap.

All models have a USFS Approved spark arrester in a oval-shaped sleeve with a large volume of packing material.

New replacement rear fender for the Gen 1 KLR650.

Available in 4 colors.

New replacement side panels specifically made for gen 1 KLR650.

Available in 4 colors.

  Will not fit KLR250

Depending on your application and preferences, more than one optional heat shield may be useful.

New Body Plastics available in Black, White, Carbon Fiber, Dark Blue, or Yellow.

Also, Currently Exclusive to ProCycle: Olive Green, and Desert Sand (complete kit only)

Includes Rear Fender, Side Panels, Headlight Cover, and Front Fender.

Choose a Kit with Maier Front Fender [pic1] or after market SuperMoto Fender (black or white only) [pic2].

• SuperMoto fender kit includes our High Mount Fender Bracket!

• The Moose Racing Adventure Windscreens are made from .118 and .177 aircraft-quality Lucite acrylic
• Heavy-duty, optically clearer than the OEM windscreens
• One version 2" taller than stock and the other 4" taller than stock!
• All units made in the USA

The Rally windscreen from Parabellum is the perfect protection from wind and debris without sacrificing technical off-road capabilities. This is an upright rally type windscreen that looks aggressive and performs well under all types of riding. Designed primarily for the off-road / dualsport enthusiast, this shield keeps pressure off the rider's chest while commuting from home to adventure and back.

Mounting is accomplished by drilling two holes on each side of your headlight cowl using the provided template. 13.5 inches tall, 11.5 inches wide at the bottom, and 8.5 inches wide at the top. Made from military aircraft grade cast acrylic.

Parabellum LTD. has continued the highly demanded Rally Shield line by fitting up the 1993-present Honda XR650L. This is an upright Dakar Rally inspired shield, designed to protect the rider without interfering with off-road riding. For on-road riding the Rally shield protects the rider’s chest from fatiguing air blasts while keeping the head in clean air. Duck behind it in the cold or the rain to keep from experiencing the brunt of the elements. During off-road riding the Rally windshield protects the rider from mud, dust, roots, rocks, or branches without becoming invasive. Whether standing on the pegs or ducking behind it, you will be impressed at the protection it offers. Their Rally shields have been tested in the toughest conditions including an entire SORCS hare scramble season.

*The Rally shield for the XR650L is 12.5 inches tall 12.5 inches wide at the bottom and 8.5 inches wide at the top and is made from military grade 1/8 inch cast acrylic.

Quality windscreen made from Lucite aircraft acrylic making it more rigid and optically clearer than OEM windscreens

This screen is 5" shorter than stock which reduces buffeting.

Factory Replacement Body Plastics from Kawasaki

This is the brace needed to stabilize the wing like structure they call a front fender on the KLR – both generations. This simple bolt-on reduces wind buffeting and increases steering stability at highway speeds. It also helps carry the weight of a fender mounted tool bag.

Made from laser cut 5052 aluminum, then CNC formed and beautified with a shiny black powder coat. Easily mounts in a few minutes using the included stainless steel hardware.

Motion Pro T-6 Combo Lever has a hex box wrench for your axle nut on one side and a perfectly contoured tire spoon on the other. Manaufactured from lightweight forged T-6 aluminum with a hard anodized finish. These beauties are just under 10 inches long and weigh only 3.5 oz. Available in a 12/13 combo unit and a 22, 24, 27 and 32mm hex ends.

These Rider's Wrenches by Fredette are combination wrenches that have three wrenches in one! A 2-stroke size spark plug wrench - a front axle and a rear axle wrench. Yep, all three in one unit.

Available in the combinations shown that will fit virtually all current dual-sport machines.

Get better range from your early KLR650 by adding an IMS 6.6 gallon fuel tank. The big tank also provides radiator protection.

Designed to enhance the appearance of your motorcycle, yet provide greater riding distance per tankful. Larger capacity than stock, yet very slim and sleek. Perfect for the dunes or the race track! These tanks are made with POLYETHYLENE CROSSLINK for extra strength and durability.

Natural color is recommended if you wish to easily see the fuel level in the tank.

This tank requires you to re-use your stock petcock valve. Does Not Use OEM/Stock Shrouds

A premium billet sprocket carrier from Warp 9 Racing that houses 2 bearings to help protect against the sideways twisting load that is commonly known to prematurely wear out the bearing and cush rubbers. This wear can cause extreme failure possibly damaging the hub.

Offered in anodized Silver or Black, Includes spacers and hardware.

These are designed to work with Warp 9 and OEM hubs.

We start with Excel or Sun rims, OEM or Warp 9 hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.

Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.

• New OEM or Warp 9 hubs with bearings and seals installed
• Excel or Sun 3.5" x 17" front rim
• Excel or Sun 4.25" x 17" rear rim
• Buchanan's stainless steel heavy gauge spokes and zinc-plated nipples

Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.

Complete set of 'Adventure' wheels. These are the same rim sizes as used by the BMW GS and other big adventure bikes. The 19" front and wide 17" rear will give you great twisty road handling on the pavement while still being dual-sport friendly.

We start with Excel or Sun rims, OEM or upgrade to Warp 9 hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.

Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.

• New OEM or upgrade Warp 9 hubs with bearings and seals installed
• Excel 2.5" or Sun 2.75" x 19" front rim
• Excel or Sun 4.25" x 17" rear rim
• Buchanan's stainless steel heavy gauge spokes and zinc-plated nipples

Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.

Complete 'Off Road' wheels for your DRZ400 SuperMoto.
We start with Silver Excel or Sun rims, OEM or Warp 9 hubs, and Buchanan's heavy gauge stainless steel spokes. Rims and spokes are precision machined for a perfect match to your bike.

Our pro shop then laces and trues your wheels to perfection, giving you the highest quality set of custom wheels available.

• New OEM factory or Warp 9 billet hubs
• Silver Excel or Sun 1.85"x21" front rim
• Silver Excel 2.5x18 or Sun 2.75x18 rear rim
• Buchanan's stainless steel heavy gauge spokes with plated nipples

Add tires to your wheel order and we will throw in tubes and mount and balance them at no additional charge.

This is the secret for being able to put in those 500 mile days. Even a good touring seat can feel a bit harsh after a couple hundred miles. These very comfortable sheepskin seat covers give you that extra bit of 'cush' and provides superior air circulation. Velcro straps allow easy install and removal when you don't need it. Measures 14" wide by 19" long, the perfect size for Dual-Sport seats.

New wider seat to help keep comfortable on that long commute or dual sport ride. The added width and foam density will help keep the seat from being an item to stop you from going on that ride or enjoying the bike. 

Check out the seat warmer we carry. Put this in before tacking your cover in place and keep yourself warm during even the coldest rides. Nothing like toasted buns to make a ride comfortable!

Available as a Foam and Cover Kit for OEM pan. It DOES NOT include the pan.

These wider seats from Seat Concepts help keep you comfortable on those long commutes or dual sport rides. The added width and improved foam density help keep your seat from being the item to stop you from going on those big rides or enjoying the bike.

The Complete Seats come fully assembled on an aftermarket seat pan, and are ready to install and ride.

This kit is not just a bulb, but an entirely new LED specific headlight! A specially designed adjustable steel mounting bracket replaces the stock unit. Included is a wiring harness and all the required hardware to make this installation quick and easy and entirely plug and play. No cutting, no drilling, no wiring modifications are necessary. The headlight features separate low and high beam projectors in a custom headlight shell designed specifically for this LED bulb.

This kit is available with either a chrome or black chrome reflector in the headlight.

Does not fit '87 TW200 because that year has a unique AC powered headlight circuit.

This kit is not just a bulb, but an entirely new LED specific headlight! A specially designed adjustable steel mounting bracket replaces the stock unit. Included is a wiring harness and all the required hardware to make this installation quick and easy and entirely plug and play. No cutting, drilling, or wiring modifications are necessary. The headlight features separate low and high beam projectors in a custom headlight shell designed specifically for this LED bulb.

This kit is available with either a chrome or black chrome reflector in the headlight.

Check out the images for stock vs. LED patterns and brightness. (Images are of a DR/DRZ unit, but the light unit is the same as that on the XRL.)

This DOT kit includes LED headlight assembly with plug-and-play wiring harness, a specially designed adjustable steel mounting bracket, and all the required installation hardware.

No cutting, no drilling, no wiring modifications! Installation takes 5 minutes.

This kit is highly recommend over the non-DOT kit. The low beam has extra punch and a proper beam pattern cut-off. The high beam throws light far and wide. It’s already a crowd favorite!

Two colors to choose from, Chrome or Black. Light output and beam pattern are the same for either color.

• Low Beam: 20W, 2,800 Lumens
• High Beam: 35W, 3,600 Lumens
• Color Temperature: 6,000k
• DOT & SAE Compliant
• CE, RoHS, ISO9002, IP67

This LED headlight from JNS Engineering is DOT approved and an entirely new LED specific headlight! A specially designed adjustable steel mounting bracket replaces the stock unit. Included is a wiring harness and all the required hardware to make this installation quick and easy and mostly plug and play. The DOT kit does not have a daytime running light (parking light) and may require minor trimming on the backside of the fairing. The headlight features separate low and high beam projectors in a custom headlight shell designed specifically for this LED bulb. The primary advantage of this kit over the original is the DOT/SAE markings and a wider high beam pattern.

Low Beam: 30W, 2,800 Lumens
High Beam: 50W, 3,600 Lumens
Color Temperature: 6,000k
DOT & SAE Compliant
CE, RoHS, ISO9002, IP67

Made from heavy duty 1/8" thick stainless steel, these mounting brackets are specifically designed for mounting 2" LED auxiliary lamps to the front of your TW200. They position the lamps (not included) high & tight to the bike for optimal protection and light projection without interfering with the bike controls, body work, or fuel tank. Kit includes four longer mounting bolts for the lower triple clamp.

The image shows a GoPro camera on the TW's right side and an LED light on the left. You could certainly do something like that as well!

Make the Edge-2 installation as easy as possible with an Optional Connector Set. This allows you to put an OEM style connector on the Edge Taillight making the connection simple. Stock plug will go right into this unit and off you go. Will need a crimp tool or set of needle nose pliers to crimp connectors on.

These low peg mounts will drop your footpegs 1.5" and move them to the rear 1" for a much more comfortable riding position, especially for taller riders. Unlike relocation plates, these mounts do not hang dangerously below the frame. You can mount stock or aftermarket pegs and they are compatible with all skid plates, crash bars, and center stands.

New 10.9 high strength mounting bolts are included. Once installed the foot controls will need adjustment and the brake switch spring will need to be slightly modified.

• Durable steel wide foot pegs.
• Made of chromium molybdenum steel for extreme durability.
• Black powder coating finish

Pro-Series foot pegs are made of stainless steel and are hard coated to prevent drooping. These pegs are 50mm x 75mm. Lo-pegs are down and back 1/4".

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 black or blue. 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. Will not work with the long or short reach choke knobs.

This is one of the gnarliest skid plate made for the KLR. Made from 3/16" aluminum, it is laser cut and CNC formed. All seams are welded on both sides and the entire plate is black texture powder coated. Includes all the mounting hardware.

This is one of the gnarliest skid plate made for the KLR. Made from 3/16" aluminum, it is laser cut and CNC formed. All seams are welded on both sides and the entire plate is black texture powder coated. The plate mounts in minutes using stainless steel hardware.

IMPORTANT NOTE: The standard kit will work with all crash bars except for Givi and Happy Trails. Select the Givi option for that brand. This plate will not work with the Happy Trails crash bars.

Select the optional heavy duty mounting brackets if you want to replace the wimpy stock mounts with steel brackets.

Mount Barkbusters standard aluminum bar handguards to 1-1/8" motorcycle handlebars with the Barkbusters Tapered handlebar saddle clamp set.

What's in the box:

• 4 peice saddle clamp set
• 2 complete saddles

These are all you need to mount your current Barkbusters Handguards when you upgrade to a tapered oversized 1 1/8" handlebar.

Designed to enhance the appearance of your TW200, yet provide greater riding distance per tankful. This larger fuel tank has double the capacity of the stock tank at 3.6 Gallons, yet very slim and sleek. This tank has a custom design that will allow the use of OEM & Maier side covers. These tanks are made with POLYETHYLENE CROSSLINK for extra strength and durability.

Comes with New Screw Cap.

Requires OEM/Stock petcock and oval rubber grommets for install.

If you do not have the grommets or if your O.E. grommets are in poor condition you can add these to your tank order.

Planning a motorcycle trip can be hard work. Butler G1 Maps highlight the best paved motorcycle rides in the country so you don’t have to guess which roads are good. Their dedicated team rides and rates every road you see on the water-proof maps, hundreds of thousands of miles so far. Their easy to read rating system clearly indicates the most dramatic and scenic stretches and are accompanied by detailed inset boxes, written descriptions, elevation profiles and whole bunch of useful information to help you plan your journey.

Looking for motorcycle road trip ideas? How about a Backcountry ride? Each of our backcountry motorcycle maps highlight the official Backcountry Discovery Routes (BDR) taking you off-road through some of the most spectacular scenery in the United States.