Our offices will be closed on Monday, September 1 for the Labor Day holiday. We will be back on Tuesday, September 2 to process your orders and respond to your inquiries.
Clymer manuals are the most user-friendly repair manuals. They are written for the do-it-yourself-er as well as the experienced mechanic by industry experts. Step-by-step instructions based on the complete disassembly of the machine. This manual in written to cover 90-94 models but nearly all of the information will apply to newer models also.
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. Contains hundreds of original photos, exploded views, drawings, specifications and charts to illustrate each job. Also features shortcut repairs and high-performance modifications.
Whether you're interested in routine maintenance tasks, troubleshooting, or more extensive repairs, the in-depth coverage provides indispensable information about your KLR650.
Your automatic cam chain tensioner is spring loaded. This can make it difficult to install as it wants to extend before you have it bolted into place. This handy tool will back off the cam chain tensioner mechanism and hold it for you. No more awkward 3-handed contortions are required to get the tensioner installed.
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.
Grab our 5-pack and save both time and money!
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.
You pay $3.59 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.
Includes forged Wiseco 83mm Piston (83.00/+4.00 10.5:1), Rings, Clips, Pin.
Top end gasket set.
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.
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.
Complete set of friction plates, HD springs and steel separator plates prevent premature driven plate wear, oil muddying and loss of stack height. Built with swaged aluminum carriers that spread the load on the clutch basket and prevent clutch basket "dogging". Anti-swell, alloy impregnated heavy-duty facings for smooth clutch action. Allows modulation, unlike paper clutches which tend to snatch. Don't forget to add a fresh gasket.
Dragging clutch? Hard to find neutral? Maybe it feels like it doesn't fully release. These problems can be caused by worn thrust washers in the clutch assembly. Most DR650s show wear on these items. Kit includes #1, #2 and #3 in the diagram.
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.
Heavy duty springs help prevent clutch slip in high-performance motors.
High quality clutch cover gasket. If you are servicing your clutch, a new gasket will prevent oil leaks.
High quality left side case gasket. If you are servicing your stator or starter clutch gears, a new gasket will prevent oil leaks.
Put fresh O-rings on your KLR when you do your next oil change. Here you have new ones for the Oil Filler and the Oil Filter Housing Cover.
Replacing your clutch or removing that side cover for any reason? You are going to need a new gasket for the cover to ensure a leak-free assembly.
Raises compression from stock 9.5:1 to 10.5:1 for more power, torque and snappier engine response. The high quality forged piston from JE is almost a full ounce lighter than the stock cast piston. This makes for less vibration and a smoother running motor. Includes rings, pin, clips, and top end gasket set with valve stem seals and metal base gasket. Fits the standard size stock bore.
Raises compression from stock 9.5:1 to 10.5:1 for more power and snappier response. The high quality forged piston from JE is almost a full ounce lighter than the stock cast piston. This makes for less vibration and a smoother running motor. Fits the standard size stock bore.
The key to getting your built DRZ/KLX motor to make big power.
High performance camshaft for the KLX/DRZ110. Higher lift and duration than stock.
Stock and typical after market drain plugs can protrude past some skid plates. This steel low profile drain plug stays inside the skid plate so it can't be snagged by passing objects.
Comes with 4 crush washers.
Extra dirt protection for your K&N filter. Our custom made oiled-foam filter sleeve wraps snugly around the K&N filter to give a first layer of protection against dust and dirt. Oil it like you would any other foam filter.
Tired of paying too much for OEM paper filters? Drive in wet/rainy weather? Get an K&N filter for your ruckus! K&N filters are reusable, waterproof, and will save you money over the life of your scooter.
Tune your stock carburetor for better power and response, easier starting and quicker warm up. Mikuni main and pilot jets.
Includes forged JE 89mm piston 10.5:1 piston, Rings, Clips, Pin, big bore sleeve and top end gasket set. You will have to have the big bore sleeve installed in your cylinder and bored to fit the larger piston.
Adhesive heat shield for your new side panel plastics to protect it from the heat of your muffler.
Depending on your application and preferences, more than one heat shield may be useful.
Dimensions: 2"x3'
Replacement side panels from ProCycle (formerly DSA). These pieces are fully compatible in any combination with the original factory plastic. These side panels have a crisper, more angular look than stock. Vacuum molded, they are a design improvement over the stock panels.
Sold in pairs
Does not include heat shield. Depending on your application and preferences, more than one optional heat shield may be useful.
Left and right stock OEM Suzuki side panels plastic sold as a pair.
Includes one heat shield. Depending on your application and preferences, more than one heat shield may be useful. Extras can be added here.
Genuine Suzuki super moto fender. A perfect match for the original gray plastic.
ProCycle Plastics (formerly DSA) Rear Fenders include LED tail/brake light and license plate holder. Vacuum molded, these parts are a design improvement over stock.
OEM Suzuki headlight cowling.
Made of military aircraft grade 3/16" cast acrylic, this guard will protect your lens from roost, rocks and branches. Optical clarity of the acrylic ensures brightness and projection of your headlight are minimally effected while all the while protecting your headlight from impact and abrasion.
Guards are held to the headlight lens with an industrial strength hook and loop system on each corner.
PSR's fin rear rotor protector. CNC machined from forged aluminum and then anodized gun metal in color. Just remove your existing caliper bracket and remove the pins, install them on this new one and then put the caliper and fin back on. It doesn't get much easier. In the event of damage to the fin, it can be replaced separately.
Warp 9's CNC shark fin rear rotor protector. To make installation super-easy this fin bolts to a brand new CNC machined caliper bracket. Just remove your existing caliper bracket and remove the pins, install them on this new one and then put the caliper and fin back on.
CNC machined from 2mm thick 5052 marine grade aluminum to protect your frame from scuffs and scratches and to keep those wandering pivot covers in place. These guards have a fine polished finish to give your DR a really classy look. These guards are supplied with all the necessary mounting hardware.
Fits Moose and other aluminum hand guards
Acerbis 5.3 gal tank adds function and great looks to your DR650. This high capacity fuel tank incorporates modern lines and high quality construction that can't be beat. Includes gas cap, petcock and all mounting hardware.
Installation of the Acerbis tank requires relocation of the front turn signals. Otherwise the stock signals will contact the tank at full lock. Our Turn Signal Relocation Brackets Move the front turn signals up and forward to clear the bigger tank.
We've been asking for a bigger tank for years and it's finally happened. This is the big brother to the very popular 5.3 gallon Acerbis tank with some modifications to add another gallon and a half of capacity. It's the same width between the knees but extends wider and further forward in front of the knee pockets. This high capacity fuel tank incorporates modern lines and high quality construction that can't be beat. Includes gas cap, petcock and all mounting hardware.
Installation of the Acerbis tank requires relocation of the front turn signals, otherwise the stock signals will contact the tank at full lock. Our Turn Signal Relocation Brackets move the front turn signals up and forward to clear the bigger tank.
Does your stock vacuum operated petcock not shut off when your bike is parked? Replace your stock vacuum operated petcock with this manual one. Must be shut off any time the bike is parked for more than a few hours. Fits stock or aftermarket tanks.
Aftermarket plastic tanks might need the hole cut into an oval shape to fit the two standpipes.
A popular upgrade from the stock vacuum operated fuel valve. Manually operated. Must be shut off any time the bike is parked for more than a few hours. Fits stock tank or aftermarket tank and has both main and reserve. Fully rebuildable.
32-Blade Dual-Reading Tapered Combination Feeler Gauge Set
Two feeler gauges with angled ends to make checking the clearances easier. Stock valve clearances are .004" intake and .008" exhaust (.10mm in. and .20mm exh.)
High quality replacement master link for the DID 428 non-oring chain
Machined from impact and wear resistant chromoly steel. Heat treated, then finished with a nickel coating for corrosion resistance.
Steel rear sprocket.
Color may vary based on manufacturer availability, quality will not be compromised.
Quality rear steel sprockets.
Individual 14T, 15T or 16T front sprockets.
JT Sprockets are made from the latest generation of computer design and control metal cutting equipment for maximum durability. Front sprockets are made from chromoly SCM420 steel alloy. All sprockets are heat-treated and hand-finished to meet or exceed the highest possible quality standards.
Fully wraps the chain to guide it onto the rear sprocket. Stainless steel hardware, anodized aluminum plate, and plastic buffer for low friction. Saves expensive engine cases.
Premium drive belts offer longer life than standard ones. A worn drive belt can affect your scooter's top speed.
Air filled AirHawk 12"x18" cushion custom fits your shape and redistributes pressure that causes numbness and discomfort when you ride. Seat cushion cover is constructed of a breathable, stretchable Nylon/Lycra blend with a non skid Urethane base. Open mesh side panels allow heat to escape. Easily inflates by mouth with no pump needed. Mounting straps and Repair patch kit included.
9" by 9" carbon fiber seat warmer that goes between your seat cover and the foam to keep your backside happy on those really cold days. This improved design produces 25% more heat than most other warmers using just 30 watts.
Kit includes the warming unit, with connector, 24" extension cable, rocker-type on/off switch and stub to splice into your wiring along with complete detailed instructions.
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.
This is a high-quality seat cover offered by Moose for the DR650. This is a replacement cover only, no seat foam and you must install on your existing pan with existing foam. Strong marine-grade vinyl that's made to last. UV protected from sunlight for extended use and has double stitching for extra strength.
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!
State-of-the-art replacement seats, Sargent seats are built on a percision-molded lightweight Polytec seat pan. Sargent's proprietary seat foam (Super Cell Atomic Foam) is their own unique blend of resilience, firmness, and vibration-absorption qualities, making it well suited for long distance comfort and support. Sargent seats are covered in a marine-grade, UV-stablized mildew resistant CarbonFX vinyl. Available in standard height and 1" lower than stock. These seats will fit bikes with the stock, IMS, or any other aftermarket fuel tank.
| Width: | 11" (279mm) |
| Height: | Same as OEM |
Check out our complete replacement tall seat assembly designed specifically for your KLX110 or DRZ110! It comes with a durable plastic seat base, specially shaped tall seat foam for extra comfort, and a sleek black non-slip seat cover. Enjoy riding with our high-density tall seat foam and the non-slip BBR seat cover for added grip.
The Phillips type screws used in Japanese motorcycles are actually Japanese Industrial Standard (JIS) screws and are easy to strip if you are using a regular Phillips screwdriver.
Here is a little kit that will make removing and replacing JIS screws much easier. Includes 2 each of JIS No. 1, No. 2 and No. 3 bits.
These will work in other bit holders and have a mild magnetic tip.
The Snap Jack is an easy to use, portable, sturdy jack for chain lubricating, adjustment and chain drive maintenance. It lifts the rear tire up to 1/2" to allow the tire to spin freely. Includes front brake locking strap.
Works on 99% of touring and sport bike models.
Features:
A must have when blazing new or old trails!
This Super Siphon has a (1/2 inch x 6 foot) long hose, which makes it quite easy to transfer fuel from one bike to another! Simply, shake the hose to prime it and get fuel moving. The hose is resistant to gasoline and any other hazardous chemicals. Roll it up, stuff it in your bag and you will be very happy whenever you need it.
Designed to seal completely around the cable housing and stop all those messy leaks. With the unit closed and sealed around the cable, your cable gets better lubrication and you waste less lubricant.
Keep your cables lubed up and working freely, with Motion Pro's Cable Luber. This tool is used to inject lubricant into any cable housing. Clamps over housing and cable allowing an aerosol can with nozzle to be connected. Once the lubrication solution runs out the far end, the cable is lubricated.
Helps protect vulnerable fork tube and seal from dust, dirt, and corrosive elements. These are sewn into a tube and require that you drop your fork tubes down out of the triple clamp for installation. Can still be slid up for easy cleaning.
32 mm-43 mm Diameter
127 mm (5") Length
3 mm Thick
Sold in pairs
Low friction 'triple lip' seal design. Oil seals last 3-4 times longer that OEM seals. Kit includes Fork Seals and dust wipers.
Complete kit to replace the bearings and seals in the XT225 swingarm pivot.
Custom developed by BBR Motorsports for the ultimate upgrade for mini four-strokes. Sized perfectly for adult back-yard racing or fast/aggressive mini riders. This is the most important upgrade you can make for an adult sized rider. The stock suspension is too soft for most adults and aggressive kids. Fits stock DRZ125 shock.
Custom developed by BBR Motorsports for the ultimate upgrade for mini four-strokes. Sized perfectly for adult back-yard racing or fast/aggressive mini riders. This is the most important upgrade you can make for an adult sized rider. The stock suspension is too soft for most adults and aggressive kids.
Sized perfectly for adult back-yard racing or fast/aggressive mini riders. This is the most important upgrade you can make for an adult sized rider. The stock suspension is too soft for most adults and aggressive kids.
Attach this over your brake lever and hand grip, squeeze the brake lever, pull the locking bar in and lock the black portion down. This creates a locked front brake, making parking safe and secure with about 5 seconds of effort.
To unlock the BrakeFix, you just lift the back of the black hooking portion to release it. This takes about 2 seconds. Perfect for use with Snapjack type stands or just parking on an incline.
Tune your stock carburetor for better power and response, easier starting and quicker warm up. Mikuni main and pilot jets and adjustable needle.
Premium quality EBC Rear brake shoes.
Replace those worn out brake pads with quality EBC replacements.
Ruckus brake shoes front or rear.
Throttle, Clutch or Speedo cables.
OEM throttle cable.
Matte black 118mm x 85mm mirrors. Similar to stock size.
• 8mm thread
Sold In Pairs
The T-6 Stainless Steel Exhaust System offers the same benefits as our popular Ti-6 Titanium Exhaust System, but the T-6 is constructed of stainless steel and aluminum for increased strength and durability while giving riders a more affordable alternative to titanium. The T-6 comes with a removable United States Forest Service (USFS) Approved Spark Arrestor making it easy to alternate between off-road and closed course riding.
Features:
This box moves up the rev limiter allowing higher revs. It also has a hotter advance curve from the OEM box. This allows for a bit crisper throttle response and easier starting. This is a "must have" for modified KLX110's.
Designed to enhance overall performance when installing a high-flow jet kit. This CDI box enhancements include:
This unit may also be used to replace a defective CDI box on a stock machine. For 1990 - 2007 models only.
These turn signal relocation brackets from ProMoto Billet provide an easy way to move the stock turn signal lights, useful if you find them getting in the way of your luggage configuration.
These brackets may utilize an existing hole in some of the rack side brackets, though many applications will require drilling or fabricating in order to mount properly.
Nomadic Racks makes this beautiful rack for the XT225. 3 piece unit that is CNC laser cut from 1/8" 5052 plate aluminum with a semi-gloss industrial black powder coat applied. Final surface space is 9 x 14 with a weight just under 2 pounds.
With all the hardware included and excellent instructions, mounting this rack to the 4 mounting points is usually no more than a 15 minute affair and no modifications are required to your XT.
There are numerous strap and bungee holds making for a very versatile little unit. It is also totally compatible with RotoPax mounting kits and Givi top cases.
You may purchase just the rack or you can order the Rack with the RotoPax Mount. If you really want it all, you can order the Rack, Mount and a Fuel or Water Container.
Locking End cap for the ProCycle Tool Tube. Mini padlock and keys included.
A pack of 10 Fuji style lock nuts to put on the sprocket of your KLR650. These are an 8 mm, flanged type nut that will keep your sprocket snug and tight.
RotoPax are Rotational Molded - the process which produces indisputably superior products.
Need to mount two containers? A water and a fuel? Two waters? Finally, you can stack multiple packs together! Use in conjunction with a pack mount. You will need to purchase the Single Mount as well as the Extender.
RotoPax holder made to mount a single Fuel and/or Water container.
Need to mount two containers? A water and a fuel? Two waters? Get the extender which allows you to stack two containers no problem! Single mount, two containers
Need to mount two containers? A water and a fuel? Two waters? Already have a RotoPax Mount for a single container? Get this extender to work in conjunction with a pack mount and that will be no problem! Single mount, two containers.
Made from strong and lightweight 4mm thick aircraft aluminum.
Protects vital engine parts from rocks and debris.
Custom fit to your specific bike model.
Oil drain hole for easy access.
All mounting hardware included.
Our Tool Tube mounts in place of the little stock tool carrier. The tube is made from 3 1/2" O.D. ABS pipe. It's held by 2 strong powdercoated steel straps. Both ends are sealed with waterproof expanding plugs. This is the ideal way to carry those items you always want to have with you on every ride. Tube is approx 13" long. Long enough to carry your Tire Iron Wrenches.
You can now order your Tool Tube with a Locking End cap, mini padlock and keys included, on the exposed end.
If you already have a Tool Tube you can order just the Locking End Cap and lock.
It is a good practice to replace your sealing washer with every oil change. These 10 piece kits are made up of 5 Copper washers and 5 Aluminum washers. The manufacturer recently decided to make half of the kit Copper washers as that is the material of choice for many OEM manufactures. This gives you the opportunity to decide which you prefer, but either will work great at creating a leak-free seal between the case and the drain plug.
A 10-pack of drain plug sealing crush washers. Replace your sealing washer at every oil change to prevent a leak.
Extra protection for your motor! Strong magnet at the end of the plug picks up metallic flakes in your oil, protecting your engine!
Extra protection for your motor. A strong magnet at the end of the plug picks up metallic flakes in your oil.
Simple, clean looking matte black mirrors have an extra long stem. Great visibility for taller riders.
Sold in Pairs
Limited to remaining quantity on hand
