CNC machined oil filler cap with locking clip to keep it in place in the roughest conditions. The cap is pre-drilled and the locking clip is safety wired to the mounting tap with a section of silicon tubing, that will not melt or discolor, over the wire. First class all the way. Available in Silver, Black, Blue or Red.
Engine
Unless you have managed to bash yours on a rock, this is an item of pure bling, but hey, there is nothing wrong with that! This CNC Oil Filter Cover is made from A7009-T6 aluminum with the 'Zeta' logo machined into the front and anodized in blue to really stand out on your Yamaha. It's also lighter than stock.
The idler gear is one of the few plastic components in the DR650 that can significantly impact engine performance if it fails or breaks.
This gear is crucial for driving the oil pump, which ensures proper oil circulation throughout the engine. In the absence of this component, complete engine failure may occur. While the idler gear is not frequently cited as a common failure point in the DR650 engine, failures have been reported, typically manifesting as either a fractured gear or stripped teeth.
During inspection, it is essential to check for any cracks, chipped areas, or missing teeth on the idler gear. Replacing the gear is a straightforward procedure, and it is advisable to do so while the clutch side case cover is already removed for other maintenance tasks, such as NSU screw replacements or clutch hub bushing replacements.
This component is a Genuine Suzuki part.
Big Bore
285cc big bore kit includes:
Wiseco piston 78.00/+5.00 10.5:1 (with rings, pin & clips):
- 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.
HotCams stage 1 camshaft:
- High-performance racing camshafts
- Stage 1 performance camshafts are drop-in cams that are designed to be used with stock valve springs
- In most applications, Stage 1 cams deliver more torque.
Complete top end gasket set:
- High-tech materials provide unmatched reliability and performance
- Rebuild the engine with total confidence as each set is designed for durability and accurate fit
- Oil seals are genuine OEM replacement seals
- Performance sets designed for a piston replacement
- Includes every gasket, O-ring and seal required to rebuild a top end; valve seals, head, base, exhaust, tensioner, and other misc. gaskets and O-rings
- Does not include formed rubber valve cover gasket
- High-compression kits use .012" thick base gaskets to raise compression
- Cost-effective way to raise compression without expensive high-compression pistons or cylinder head work
- All gaskets made in the U.S.A.
This is a great combination and a big 'bang for the buck' performance increase.
No re-sleeving required. You will have to have your cylinder bored to fit the larger piston.
Clutch
Replace your worn out clutch with a high quality Clutch Kit. This kit includes new friction discs for your clutch pack.
Please note: kit includes friction discs only, steel plates and springs not included.
Drain Plug
- Bolts are CNC-machined from high-quality aluminum
- Embedded magnet helps keep bolt in place
- Pre-drilled holes make for easy installation of safety wires
Gasket
Rebuilding your engine? Here is a complete gasket kit for your TW200. 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, Exhaust Gasket, Left and Right Side Cover Gaskets, Pump Cover Gasket, TDC Plug O-Ring, Crankshaft Nut Plug O-Ring, and Oil Filler Plug O-Ring.
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
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.
Oil Filter, Drain Plug
The Total Tune-Up Kit. All the parts you need to do a complete tune-up on your beloved beast.
- Valve Adjustment Wrench
- Feeler Gauge set taper blades (.0012"-.040")
- Breather Filter
- 5-Pack of Oil Filters
- Magnetic Drain Plug
- O-Ring Kit
- Air Filter
- Spark Plugs
Exhaust
Muffler
The DG RST (Reduced Sound Technology) muffler is the quietest DG muffler and is designed especially for dual-sport machines (Just 89db @ 3200 RPM). A new baffle design dissipates sound waves reducing noise output in a very efficient manner. This new design also stretches out the time between muffler repacks. Included is a Stainless Steel mid-pipe, USFS Approved Spark Arrestor and a new Aluminum end cap.
You may want to consider a new exhaust gasket that goes between the header and the muffler.
The new DG RST (Reduced Sound Technology) muffler is the quietest DG muffler and is designed especially for dual-sport machines (Just 89db @ 3200 RPM). A new baffle design dissipates sound waves reducing noise output in a very efficient manner. This new design also stretches out the time between muffler repacks. Included is a Stainless Steel mid-pipe, USFS Approved Spark Arrestor and a new Aluminum end cap.
You may want to consider a new exhaust gasket that goes between the header and the muffler.
Tires
Tubes
Our Heavy-Duty tubes are made specifically for off-road riding. These are the sturdiest, highest quality tubes on the market. They are 3mm thick with natural rubber construction to better resist pinch flats and are easier to patch than butyl rubber tubes. These have a straight metal valve stem. New tubes deserve new rim strips. Don't forget to add them in to your order.
- 17" tube works with 120,130 and 140 metric tires or 4.50 to 5.10 inch size tires
- 18" tube works with 100 to 130 metric or 4.00 to 5.10 inch size tires
- 19" tube works with 100 to110 metric or 4.00 to 4.60 inch size tires
- 21" tube works with 80 to 100 metric or 3.00 to 3.50 inch size tires
Replacement Inner Tubes for your VanVan or TW200. Always a great idea to carry a spare on your adventures as the rear tube is often hard to find.
We offer two different types of SuperMoto tubes. The first are Standard Tubes and are meant to be used with standard bias-ply type tires, but can be used with radial tires also.
But, if you are running radial tires, like SuperMoto, or have a retro bikes with spoked wheels and radial tires, you probably want to run the 'Radial Tubes'. Front tubes fits 120/70 and 120/60 tires. Rear tubes fits 150/60, 150/70 and 160/60 tires. These have a metal valve stem.
Dual-Sport
Made for the true adventure rider, the K784 has everything you need to get you anywhere on or Off-Road.
- Tread pattern providing high traction on a variety of terrain
- Large tread blocks for improved tread wear and high speed handling
- High impact, Bias ply, casing structure providing a high level of puncture resistance
- Bias belted casing for improved handling & stability
- Rubber compound designed specifically for wet-slick & dry-hard packed terrain
- Picture provided for purpose of viewing treads.
Pirelli's Corsa radial or bias-ply with maximum grip tread.
Superb corning and straight-line stability.
Exceptional wet-weather performance.
Tubless design.
This is a great Dual-Sport tire from Dunlop. Designed for the true 50/50 rider. An Adventure product for the price-conscious customer. Full tread depth pattern designed for rigorous off-road use yields excellent traction on everything from hard-packed fire roads to soft single-track trails. Versatile tire performance allows riders to travel on the street and venture off-road. A tire equipped to go anywhere, the D605 is a value option for the all-around rider. DOT approved.
Shinko 700 Series tire features an aggressive 60% on-road and 40% off-road read pattern for good dirt riding performance, without sacrificing pavement grip. Other features:
- Aggressive tread pattern with drop lug construction
- Heavy-duty 4-ply carcass for durability
- Reinforced side knobs for cornering stability
- DOT approved
Engine, Electrical
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
Chemicals
Hydraulic Clutch Bleeder Kit includes 2oz of Magura Blood clutch fluid, 2 bleeder tools and fittings to properly bleed your hydraulic clutch. Great if you have air infiltration in the system or damaged it in some fashion.
Gas Tanks
Fuel Line
Hose reducer to go from 5/16" line down to 1/4" line. Many bikes have 5/16" carburetor spigots but most aftermarket petcocks are 1/4". This solve the problem of mismatched sizes. Solid brass construction. Can be used to route or repair fuel lines, oil lines or air lines. Barbed ends provide a secure fit.
Fits all TW200's. Includes a new cap and uses the stock petcock. Capacity is 2.7 gallons (stock tank is 1.8 gallons).
Clarke tanks do not come with a vent hose or vent cap.
Please note: All Clarke TW200 tanks have blemishes due to the mold used in their manufacturing process. Also, side panels are likely to not snap into tank as they do on the stock tank.
The new 4.1 gallon fuel tank from Clarke. Carries almost 2 more gallons than the stock tank. Available in Blue, Black, Silver, White or Natural
Accessories
We worked with TechSpec to have them make custom tank grip pads that look great on both Acerbis (5.3 and 6.6 gal.) and IMS tanks. These pads not only cover those ugly scuffs, but give great knee grip to the slippery plastic.
These have been tested on two of our shop bikes for over 3 years, they did not bubble or peel off in any way.
Security for your fuel tank. Includes 2 keys. Internally vented with a check valve that prevents spillage in case of a tip over.
This CNC cap will replace the stock gas cap on the stock tank. You do need some parts from the stock cap, so don't throw it away yet! It is not difficult and this kit includes the additional hardware required. Also included is a vent tube with a matching cap.
For use on STOCK TANK ONLY! This is NOT a locking cap.
Does not fit California model DR650
If you're like us, you hate the long floppy vent hose hanging off the cap of your aftermarket tank.
This one-way vent cap replaces the long hose with a short one only about 2" long. It allows air into your tank but prevents fuel from sloshing out.
Machined from billet alloy and anodized for good looks.
Not for stock fuel tanks!
If you need a replacement cap for your Acerbis tank, why not go bling? These caps have a carbon fiber pattern molded into them that is extremely realistic. Looks like the real thing. Topping off the cap is a CNC Machined metal vent cap. This eliminates the need for a lengthy vent tube that gets in the way. The vent cap allows air to vent into the tank but does not allow fuel to splash out during normal use or during a tip over.
These caps fit Acerbis tanks only.
Fuel and Intake
Air Filter
A quality foam Air Filter to replace the stock one. Uses the same guide and frame as the stock unit. It requires foam filter oil to properly trap dirt particles. Don't forget the Evolution Air Filter Oil kit from No Toil.
- 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"
- 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"
- Unique triple stage foam filter designed for the most extreme conditions
- Eliminates the need for power robbing dust covers and outerwear covers
- Increased protection against silt, water, and sand
- Allows for extended filter service intervals
- Can be cleaned, re-oiled, and re-used like a 2 stage filter
- Used by factory off road teams around the world
Hiflo filtro air filters are manufactured to fit the factory air box and are a direct replacement for original equipment filters. Top quality powerflow filtering media, developed for modern high performance engines.
Here's a UNI dual layer foam air filter element to fit our TW200s. Needs to be treated with air filter oil like any other foam filter.
EFI Controllers
Replaces the stock 2 wire Ruckus fuel level unit with a 3 wire unit that allows use of a multi-level fuel gauge.
Carburetor Repair Kit
Here is the O-Ring that fits in the carburetor manifold. This is the manifold that holds the carb up to the cylinder head. The O-Ring mounts between this manifold and the cylinder head. When this O-Ring fails it allows air into your cylinder and makes your Air Fuel ratio too lean which causes the engine to run too hot.
Carburetor
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 genuine TM40 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.
Controls, Brakes
Levers
This anodized billet piece, brings a touch of color to your bike. Available in red or blue, it replaces the stamped steel clevis that connects your brake pedal to the master cylinder.
Armor - Bike Protection
Skid Plate
Protect your Kawasaki KLX250 or KLX300 with T-Rex Racing's heavy-duty skid plate engineered for maximum durability and performance. This premium aluminum skid plate shields your bike's engine and undercarriage from rocks, roots, and trail debris during aggressive off-road adventures.
Precision-manufactured for perfect fitment, this bolt-on protection features reinforced mounting points and lightweight construction that won't compromise your bike's agility.
Easy installation with included hardware makes this essential upgrade perfect for trail riders, enduro enthusiasts, and dual-sport adventurers seeking reliable undercarriage protection for their Kawasaki motorcycle.
These plates are made from 4mm thick 5083 aluminum because the extreme abrasion and impact resistance for the full weight of the bike and the rider. The front portion of the B&B Skid Plate bolts to mounts that are permanently attached to the forward motor mount. This means no more trying to hold clamps in place when you take you skid plate off for oil changes or cleaning. Easy off, easy on. All necessary hardware is included in the kit. The plate has foam or rubber wherever there is contact with the frame.
Choose from a polished finish or a black polymer coating.
Brake Guard
B & B Off Roads Kawasaki KLR 650 master cylinder guard is made from 2mm 5052 marine grade alloy and CNC machined in one piece for strength. All guards are supplied with all necessary mountings and stainless bolts. Made to cover and protects the rear brake master cylinder it looks great and is easy to install. Choose between polished or black polymer finish.
Chain Guard
Handguard
The Rally Pro X-Strong features a high-impact, composite injection-molded outer guard surrounding an anodized aluminum inner guard. It is equipped with an indexed steel bar-end insert that ensures a secure installation, preventing Rally Pro handguards from slipping, even in challenging conditions. Additionally, a compact integral spoiler is incorporated into the design. The package includes a robust universal silver mount kit that is compatible with 7/8” (22mm), Pro Taper 1 1/8” (28mm), Magura, and Twin Wall aluminum handlebars.
Some models with adjustable windscreens may need the windscreen rotated forward, such as the Royal Enfield Himalayan, to avoid contact at full lock. These are not compatible on Honda CB500X's and Honda Africa Twins.
Radiator & Oil Guard
Radiator guards from Devol Racing protect your radiators from damage due to trail side objects and roost bullets. They offer protection not just from frontal assaults but also from those tricky side attacks. Made from high-grade aluminum alloy for light weight and strength, these guards have an improved air-flow design that eliminates any overheating problem. A solid mounting to the frame make these stronger than most guards that just mount to the radiators themselves.
Devol Racing makes a super product that will keep you on the trail for a long time.
Lighting
Turn Signal
If you just installed aftermarket LED turn signals or an LED integrated tail light and your turn signals are flashing way too fast, or perhaps simply staying on completely, you're at the right place to find the solution! The TST Gen2-SK LED Flasher Relay fixes what we call "hyperflash". It slows the flash rate down to a pre-set 85 cycles per minute but can be sped up or slowed down using the adjustment dial located within the unit so you can get the exact speed you are looking for. The plug-and-play installation means that you don't need to splice in any load balancing resistors that generate unnecessary heat and require splicing into your stock wires. Simply remove the stock relay and install your new TST relay and your wiring job is done. It's that simple!
- Slows turn signal flash rate down to an adjustable 85 cycles per minute when turn signals are experiencing hyperflash or stay on continuously
- Adjustable turn signal flash rate enables you to speed up or slow down the flash rate to fit your preference
- Plug and play installation meaning no cutting, splicing, or soldering
- Replaces the stock relay and fits like OEM
- No need for cumbersome and heat-generating load balancing resistors
- Flexible relay housing enables easy access to the flash rate adjustment dial inside of the relay unit
Please make sure your bike uses a 2-pin relay for the signaling system. If your bike has hazard lights it may need the 4-pin relay. Please also note the pin configuration and make sure it matches what is on your bike. It is very important to verify fitment before making your purchase.
Reproductions of the original DR650 factory turn signals. Save a bundle compared to the $70+ each cost of the OEM signals. The wire pigtails plug directly into the factory harness. No cutting or splicing necessary. Choose original style amber lens or clear lens with amber bulb.
Headlight
This kit includes a DOT LED headlight assembly with plug-and-play wiring harness, a specially designed adjustable steel mounting bracket, and all the required installation hardware.
How does this headlight compare to our original TW200 kit? First and foremost, this kit has SAE/DOT markings and a much wider/brighter high beam pattern. The low beam is very similar to our original kit: wide, flat, and bright but with more punch. The DOT headlight assembly has also proven to be more durable than the original headlight.
Low Beam: 30W, 2,800 Lumens
High Beam: 50W, 3,600 Lumens
Color Temperature: 6,000k
DOT & SAE Approved
CE, RoHS, ISO9002, IP67
No cutting, drilling, or wiring modifications! Installation takes 5 minutes.
Two colors to choose from, Chrome or Black. Light output and beam pattern is the same for either color.
Please note that this product is not compatible with the 1987 TW200.
Tail Light
Taillight and brake light Attaches to the top of the rear fender. Dimensions: 3 1/2" wide x 2" long x 3/4" tall. D.O.T. approved.
Seats
Complete Seat
Seat Concepts seats are constructed using a foam material that is a much higher quality than OEM seat foam. Their proprietary formula provides a more plush and active ride, while still offering the necessary amount of support. Their unique comfort shape maintains a similar contour to stock at the front of the seat so the rider’s legs are not spread farther apart, but tapers out towards the mid-point to distribute rider weight over a greater area.
These features combine to offer a custom seat feel, and provide greater enjoyment and increased range on a long commute, or Dual-Sport ride!
Width: | 9" (229mm) |
Height: | Same as OEM |
Seat Concepts seats are constructed using a foam material that is a much higher quality than OEM seat foam. Their proprietary formula provides a plusher ride, while still offering the necessary amount of support. Their unique comfort shape maintains a similar contour to stock at the front of the seat so the rider’s legs are not spread farther apart, but tapers out towards the mid-point to distribute rider weight over a greater area.
Complete seats are built by Seat Concepts on a new seat pan and come ready to be installed on your bike.
Width: | 10" (254mm) |
Height: | Same as OEM |
Body
Windscreen
The touring windshield from Parabellum has been designed, developed and tested using all the knowledge and experience of the KLR riders in their own shop. Using the stock mounting points as well as the cowling mounts increases the rigidity of the shield.
All new fasteners are included. This new design allows you to move your handlebar to different positions and will not interfere with a stand-up position for off-road use.
This shield is constructed of 3/16" military grade cast acrylic that is 17 inches wide at the bottom tapering to 16 inches at the top.
Transform your ride. MadStad's patented mounting system allows riders to adjust the height and angle of their motorcycle windshield resulting in much smoother airflow, better wind protection and a more comfortable ride than any fixed windshield can provide. Better still, this dual-sport version pivots the shield down and forward to get it out of your way for off-road riding!
What's included in the kit:
Their complete bolt-on system is custom-made for your bike and includes everything needed to mount and position the shield. Your bike will not require any modification.
- A set of MadStad adjustable dual-sport brackets
- 3/16" (4.5 mm) thick cast acrylic windshield.
The MadStad brackets bolt to the top of your fork clamps and are completely free of the handlebars. You can adjust the shield for the optimum height, angle and airflow for comfortable street and highway riding. When going off-road you can leave your comfort adjustment as-is and pivot the entire system down and forward in front of the headlight so you can get it out of your face completely. When it comes time to hit the pavement again, simply pivot it back up and you are back in street riding comfort mode.
Rear Fender
Complete Kit
High-quality, direct replacement plastic kit includes:
- Front and rear fender
- Side covers
- Air box cover
- Radiator shrouds
Yellow kit is only available with white side covers
Add-on Headlight cowling fits S and SM models not "E" offroad model
Includes new Suzuki side panels, heat shield, headlight cover, rear fender and your choice of aftermarket off-road or supermoto front fender.
Choice of off-road or supermoto (SM) front fender.
Blue kits come with white side panels.
Freshen up the look of your TW. New Plastic in Black or White. Includes Rear Fender, Side Panels, Headlight Cover, and Front Fender.
Choose a Kit with OEM Front Fender or after market SuperMoto fender.
SuperMoto fender kit includes our High Mount Fender Bracket!
Front Fender
Universal design comes undrilled without mounting holes, allowing it to be custom fit to your bike.
Vents in the back improve airflow to motor. Smaller front reduces 'wind steer' and improves high speed stability.
Refer to pictures for color and fender design.
Chemicals, $25 and Under
Filter Oil & Cleaner
This advanced filter oil & cleaner kit by No Toil is alcohol free, completely biodegradable and compatible with all foam filters.
- Offers superior protection
- Waterproof yet easy to clean
A six step maintenance system designed to recharge any K&N air filter.
- Completely restores airflow efficiency
- Kit includes filter oil, and filter cleaner
- For K&N filters only
Adhesives
ThreeBond 1342 low strength thread locking compound. This is the ideal retaining compound for small nuts and bolts. Fasteners are held securely but, can be easily removed when necessary. ThreeBond gives this a number 4 rating for exposure to engine oil making it a good choice for internal fasteners as well as external fasteners. 10ml bottle.
Suspension
Swingarm
Shock
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.
Shock Spring | Qty 1 |
Spring Adapter Collar | Qty 2 |
Spring Adapter Collar 2 | Qty 1 |
8.0 kg/mm is 24% stiffer than stock
- 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
Fork Seals & Bushings
Kit includes all the fork bushings, o-rings, snap rings and washers. This kit comes with what you need to completely rebuild your front fork bushings.
- Patented fork seal features a balanced 3 lip design that evenly distributes the pressure reducing operating temperature, wear and friction
- Custom Elastomer Fork Seals have been tested to outlast OEM fork seals. Extends typical seal life by 3 to 5 times over OEM seals
- Stiction (friction) measures from 1/3 to 1/2 less than OEM seals for smoother fork action
- Lower Stiction, Longer Life! It doesn’t get any better than this!
- Plus, the only complete line of dust wipers! Wipers should be replaced with the fork seals to assure peak performance
Forks
The complete fork upgrade kit - your choice of springs and Race Tech Gold Valves. Also includes a set of top quality fork seals and 5W fork oil to complete the job. Everything you need to transform your mushy stock forks into suspension that really works.
You can select from various straight rate springs to customize the package to your needs.
Stock Spring Rate for XR650L: 0.44 kg/mm
Here is everything you need to upgrade your TW200 front suspension. Kit includes: Heavy Duty Fork Springs, Cartridge Emulators, Oil Seals, Dust Seals, and 10w Fork Oil. Just choose the spring rate you want and enjoy your TW even more!
Stock Spring Rate is .50 kg/mm. The .60 kg/mm springs are 20% stiffer than stock while the .70 kg/mm is 40% stiffer than stock.
Installation requires disassembling your forks and drilling out your damper rods.
Fork Cartridge Dampers
Damping Rod style forks are notorious for being too harsh, too mushy and too easy to bottom. Gold Valve Cartridge Emulators remedy this problem by controlling the compression damping with a tuneable valve. The Emulator sits on top of the damping rod and is held in place by the main spring.
Simply put; Emulators make damping rod forks perform like well-tuned cartridge forks. Installation and tuning for any condition or rider preference is very straight-forward.
Simple to install and completely tunable for all conditions and rider preferences.
Brakes
Pads
- Front pads: Sintered Pads are best for regular riding. Long life, and good performance in all conditions
- Rear shoes: Organic brake pads contain man-made high-performance fibers that are used for their light weight, high strength abrasion resistance and thermal stability.
Controls
Levers
MAGURA HYMEC – AN EASY TO INSTALL ALTERNATIVE TO A MECHANICAL CLUTCH.
This system replaces the clutch lever and cable – with a small lightweight hydraulic system for improved clutch control. The Hymec ensures an easier operating pressure, a constant pressure point, no more cable adjustment and smooth clutch actuation to ensure the perfect take-off every time. Hymec significantly improves vehicle performance – it allows the user to feel the point where the clutch releases and actuates. This product has been developed over many years and been tested under the toughest conditions possible in the world of motorcycle off-road sport. It has been used by world champion riders who all agree as to the benefits but it is just as useful to the complete novice who stalls at the traffic lights.
- This system replaces the clutch lever and cable – with a small lightweight hydraulic system for improved clutch control
- Up to 20% less clutch pull
- No maintenance and self-adjusting
- Smooth hydraulic feel with clear and consistent pressure point
- Operates on mineral oil which doesn't draw moisture and won't harm paint or finish
- Forged break-away lever blade with reach adjust is ready to mount
- Clutch safety switch included
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.
Replace your Bent or Broken Levers.
- Meets or exceeds OEM specifications
- Made from aircraft A-360 die cast aluminum
TW200 fitment 1987-2000 year models with Drum Front Brake or 2001-2014 year models with Disc Front Brake.
- Polished aluminum finish
- Quality Aircraft grade A-360 aluminum for strength & durability
- Designed to exceed OEM specifications, built to resist breakage
- Durable hard coating
- Designed to fit OEM perch
- Image is for reference only, actual product may vary for your application
OE style clutch lever.
- Quality Aircraft grade A-360 aluminum for strength & durability
- Designed to exceed OEM specifications, built to resist breakage
- Durable hard coating
- Designed to fit OEM perch
Cable
Direct replacement cables for your T-Dub. OEM or high-quality replacements will keep you on the road or trail. Pay attention to the model year for correct fitment, then select the cable type: Throttle, Clutch or Speedo, they're all here.
Handlebar, Bar Risers
Comfortable Oversize (or Fat Bar) Handlebars.
- CR High Bend
- Black in color.
- Made from 5mm, proprietary, 2000 series T6 aluminum alloy for superior tensile and yield strength.
- Lighter and stronger than regular bars
- No-crossbrace allows flex to reduce shock and rider fatigue
- Oversize 1-1/8" diameter base reduces to 7/8" to allow standard-size controls/grips
- Etched alignment marks for fast and accurate positioning
- Bar pad included
- Works with stock controls and cables.
For bikes with factory 7/8" handlebars these will require the use of a 7/8 to 1-1/8 adapter (sold separate).
Electrical
ProCycle Dashboard designed to power multiple electronic devices. It can also be used for accessory lights, heated grips or gear, whatever you like.
The dash panel is manufactured from laser cut 5/64 mild steel and powder coated black. Also included are 2 weather resistant green LED rocker switches, a voltmeter with (two) 2.1 amp weather resistant USB ports, a wiring harness with a built in fuse/holder, and complete instructions. Everything you need to mount it and connect the bikes electrical system.
Battery
These are the first batteries with built-in jump starting. They intelligently monitor their status, and just before going completely dead, puts itself to sleep with just enough energy to get your vehicle started again. Simply press the RE-START button located on the battery, start your bike and ride away.
These are an extremely lightweight (2.5 lbs.) high-powered Lithium-Ion replacement battery for motorcycles. These batteries offer the first Battery Management System (BMS) found on a powersport battery and includes low-voltage cut-off, over discharge, over-charge, and thermal protections with real time lithium-ion cell balancing. Use of a lithium specific charger to maintain the life of the battery is highly recommended.
Product Size is 8.4"L x 5"W x 2.2"H. If you need spacers, select the optional Foam Kit to pad the battery in the battery box.
Featured Products, Frame
Footpegs
Motion Factory Racing patented Flex-Mount Footpeg System provides superior grip and allows your foot to flex forward and back with the movement or your motorcycle.
One of the key features of Flex-Mount Footpegs is their unique flex-mount design. This design allows the footpegs to absorb shocks and vibrations, reducing fatigue and improving overall comfort during long rides. Additionally, the adjustable height and angle options ensure a personalized fit, allowing you to find the perfect riding position for maximum control and stability.
The bushings act like the suspension on your bike. With bushings, there are a couple of things to think about. The more firm the bushing the more durable and longer it will last. They use a durometer, a hardness scale 0 being the softest and 100 being the hardest. They don't go below a80 because they found that durability isn't great below this but have tested as low as a60 bushings. A bigger person that rides enduro-style terrain might want an a96 or a98 rated bushing. A lighter person might want the opposite but in the end, it comes down to personal preference.
They put an a90 bushing on all new mount setups so people can get a good feel for their mid range option. The bushings are high quality yet inexpensive (they achieve this because they use skateboard bushings that are already developed and produced in massive quantities around the world) and a wear item designed to be replaced each season or depending on how hard or often someone rides.
Complete mount system includes:
- 6061 Aluminum ADV Platforms (65mm wide x 107mm length)
- Stainless steel mounts
- Sleeve bearing (8x10x20mm) included for 8mm OD' footpeg pins.
- Right and Left spring included.
- Chromoly steel spindles with reusable thread locker. 14mm wrench. Torque spec 40 ft/lbs
- A90 (medium flex) rated bushings
- Cleats and stainless steel machine screws. M3x18mm. These can simply be replaced by going to your local hardware store when damaged or worn out.
- Bushing bolts. 8mm Allen wrench. Torque spec 30 ft/lbs
They designed their hardware to bend rather than break in a significant impact. A wrench or adjustable wrench will quickly and easily bend the bolt back straight. Please avoid using a hammer. A little leverage from a long-handled wrench or pipe will do the job. The whole system is rebuild-able and serviceable.
They Fit Kawasaki KLX110 and Yamaha TW200 however some of these bikes may need a little modification by yourself, Please check the size carefully before you buy. If you make mods to the footpegs for fitments it will void all warranties and return policies.
Frame
Footpegs
2 high-quality bushings per set. They recommend changing bushings every 40 hours or at least once a year to get the best performance out of a set. If you are on an Adventure Bike and are doing a lot of road miles they recommend swapping out bushings once a year to ensure that you get the most vibration dampening of the bushings.
Every new set of pegs comes with a 90A bushing installed. This is a medium flex rating.
80A is the softest and 95A lock-out is the stiffest and has the least amount of flex.
The bushings act like the suspension on your bike. With bushings, there are a couple of things to think about. The more firm the bushing the more durable and longer it will last. They use a durometer, a hardness scale 0 being the softest and 100 being the hardest. They don't go below a80 because they found that durability isn't great below this but have tested as low as a60 bushings. A bigger person that rides enduro-style terrain might want an a96 or a98 rated bushing. A lighter person might want the opposite but in the end, it comes down to personal preference.
The bushings are high quality yet inexpensive (they achieve this because they use skateboard bushings that are already developed and produced in massive quantities around the world) and a wear item designed to be replaced each season or depending on how hard or often someone rides.
For use on Motion Factory Foot Pegs Only
Lighting, Body
License Plate
License plate bolt with bright white LED light. The simple way to light up your plate.
- License plate mounting bolts in a hex shape
- White LED light in the center of each bolt
- Non-flashing, made for continuous on, to light license plate
Drivetrain
Sprocket
High quality sprockets
- Stock size is 14 tooth
- Add teeth for highway riding
- Subtract teeth for low end gearing
Counter shaft sprocket replacement requires the removal of the left side case cover. A new gasket may be required. This is also a great time to replace that leaking oil seal!
Quality steel sprockets and EK SROZ2 525 O-Ring chain. Available in gear ratio choices from - 13/42 to 15/46. EK SROZ2 525 chains come in 120 link length and may have to be cut down to fit. They also come with rivet type master links. Clip type links are available below.
13 and 14 Tooth sprockets require a smaller retainer
Chain
High Quality chain. Will need to be cut to fit your sprocket combination.
Lower friction and longer life. X-rings have twice the sealing ability as compared to o-rings. They do a better job of keeping the lube in the links and the dirt out. DID VX chains have a reputation for being the best chain you can buy for dual sport riding. DID VX chains come with rivet type master links.
High Quality chain. Will need to be cut to fit your sprocket combination.
All of these chains come with a clip type master link.
Always carry a spare master link when out on the trail.
Master links are not interchangeable. Be sure to check the manufacturer and series on your chain.
These do not fit the TW200 or XT250. Only for 520 or 525 chains, Please verify chain size.
Luggage
Straps
You can add this cam buckle loop to any 1" flat webbing system and have an instant secure way to tighten your load.
Available in 6 colors.
CONSTRUCTION FEATURES
- Heavy Duty Cam Buckle rated for 2000 pound load capacity
- 1" Flat Nylon webbing
You can add the double D ring loop to any 1" flat webbing system. This simple piece adds a lot of flexibility to any luggage system you are using. Instantly and easily create a mount point or adjustment point on almost anything. Double D Rings can be used as a secondary buckle and works the same way as a helmet strap. However, the double D rings should NOT be used as a primary means of securing luggage.
Available in 6 colors.
CONSTRUCTION FEATURES
- (2) Heavy Duty 1" Metal D Rings
- 1" Flat Nylon Webbing
Luggage Racks
The Front Rack gives a lot of options for functionality.
CycleRacks are made out of Schedule 40 11/16 black steel pipe, bent in a press, and welded together in a jig.
All of their products are 100% made in the USA. If the rack is ever broken for any reason, CycleRacks will replace it for free, you just pay the shipping.
Hazardous, Tires
Tire Tools
All that you need to repair and inflate your tire on the road or trail.
- Padded nylon zippered carrying case easily stores inside fanny pack or tool compartment
- Everything needed to repair and inflate tire on the road or trail
- 4" inflator hose accepts threaded cartridges only
- Each cartridge produces 8-9 psi
- Made in the USA
Kit includes:
- 1 - large oblong patch
- 2 - medium size patches
- 3 - small patches
- Thumb buffer
- 0.50 oz tube of rubber cement
- 5 - 4" rubber insert strips
- Insertion tool with screwdriver handle
- Reamer/rasp tool with screwdriver handle
- 3 - 16 gram 3/8" threaded CO² cartridges
- CO² 4" inflator hose
CO² cartridges cannot be transported on an aircraft.
Controls, $25 and Under
Grips
ProTaper Pillow Top Grip with 3-D (Tri-Density) Technology. Try the grip with the technical advantage of three dedicated rubber compounds.
- Vibrasonix pillow top reduces vibration and cushions impact.
- Inner core compound perfects the bonding interface with bars.
- Anti-Rip Tip™ uses denser compound to increase life of grip.
- Designed to self-clean and shed mud away from outer surface.
- Tacky gel-like surface compound is perfect for the trail and MX.
Engine, Tools, $25 and Under
Engine & Maintenance
Special tool to remove the flywheel/rotor from the end of the crankshaft. You have to remove the flywheel/rotor to upgrade the doohickey.
Engine, Tools
Repair Manuals
This Official 2001-up Yamaha TW200 Trailway Factory Service Manual provides repair, maintenance and service information for 2001-up Yamaha TW200 Trailway motorcycles. Most of the information is useful for the 1987-2000 models as well.
Clymer repair manuals provides step-by-step procedures based upon the complete disassembly of the motorcycle. This hands-on experience combined with extensive research results in a manual that is both user-friendly and detailed. Hundreds of original photos and illustrations guide the reader through every job.
Clutch, Engine & Maintenance
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.
Tires, Tools
Tire Tools, Wheel & Tire
No more fighting to keep the bead down while installing or repairing your off-road tires. The Bead Buddy holds the tire bead down in the drop center of the rim during tire changes making changes as easy as possible. Machined from tough 6000 series aluminum the Bead Buddy is light weight and compact enough for any tool pack. The Delrin securing thumb screw insures no scratches to your rims.
The Bead Buddy is NOT recommended for use with Bib Mousse tubes.
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.
Accessories, $25 and Under
Cat Crap is the #1 voted anti-fog on the market. Lens cleaner and anti-fog in one. Works for all lenses, eyewear, goggles, helmet visors, etc.