Multisurface Motorcycling

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THE SUZUKI DR650 PAGE
June 2003\| Multisurface Motorcycling.com

(Revised June 2004, added DR650 Consumer Alert Update)

Overview of the Suzuki DR650
by Elden Carl

I'm closing in on 250,000 miles on DR350's, KLR650's and a DR650. My 2002 DR650 will turn 20,000 miles today. The DR650 is presently my only single surface motorcycle and only occasionally gets off the pavement. Why? Because it's one heck of a back road scoot.

The DR650 has the best single cylinder engine I've ever had in a bike. I run the doggie doo doo out of it and it never complains. It's the only air cooled engine that maintains power no matter how hard its run. Its a great little canyon scratcher.

Besides being tough the DR 650 engine appears to be long-lived. I've heard of the 60,000 & 75,000 mile DR650SE's. Oil consumption is more like Pauline's Crown Vic than any other bike I've ever owned (Read nearly none) If you're 5'9" or shorter then the DR650 has great multisurface potential with some work done and changes made. It is possible to adapt a cartridge front end and light dirt rear wheel, but that's a subject for another article.

Additional topics
on this page:

Elden's Modifications

Known issues

Future upgrades


Elden's Suzuki DR650 Modifications by Elden Carl
Installed a Acrebis 4 gallon plastic gas tank and modified the seat for more comfort. (Read wider and thicker) NBI upholstery's (see links page) Mike Brunton did the work.

Installed a modified factory rear rack.

Installed the factory bash plate.

Installed lowering links and modified spring collar, which were made by Eagle manufacturing. Note: The modified spring collar limits the suspension travel to prevent the rear wheel from hitting the inner fender after the links are install.

Had Eagle manufacturing (see links page) zirk the rear suspension linkage, swingarm and brake pedal to my specs.			DR650 w/ zerk fittings upgrade on the rear suspesion.
DR650 swing arm w/ zerk fitting	DR650 swing arm level shaft w/ zerk fitting	DR650 level body and shafts w/ zerk fittings	DR650 rear brake lever w/ zerk fitting


Replaced the lower chain wheel with the small White Bros. unit equipped with sealed bearings

In addition, I did the following upgrades to the suspension and wheels (images coming soon) Had Bob Bell at Precision Concepts Racing hard anodized the rear shock body and custom modify the dampening setup. Changed the front fork oil viscosity and level according to Bob Bell's specs. (Forget the fork brace! It works great W/O one!) Buchanan's heavy duty stainless spokes and nipples in both wheels. Installed Avon Distanzia tires front and rear. (What a Bitchin' street tire)

Known issues on Suzuki DR 650 by Elden Carl The DR650 has a pretty good history since 1996, but isn't perfect. The engine has been plagued by base gasket leaks until this year (late 2004) when they finally installed a special steel base gasket coated with some magic black stuff similar to what is used on the head gasket. The leaks should stop, we hope. The 6mm threaded holes that you screw the valve cover bolts into tend to be soft, so don't exceed the torque specs. The DR 350 has the same problem so I used Time-Serts® on all of the holes and will do the same to the DR650. The 1998 and part of the 99 model year's had faulty starter mechanisms causing the engine cases to crack if the engine backfired. Avoid these years if you buying a used one or demand a left side inspection under the covers. If the cases aren't cracked, the 2003 improved parts can be retrofitted to solve the problem. *Update !* Suzuki has finally started using the new upgraded steel base gaskets on the 2004 DR650. You can identify the steel base gasket by two small rivet tabs that are located on each side of the cylinder at its base. Do not accept the 2004 DR650 with the fiber base gasket; as they often fail and cause serious oil leaks.

Future upgrades: by Elden Carl The next step is to have Buchanan's install a 19" front rim and a 18" rear along with their stainless steel spokes.