r/dr650

My brother bought a used 2022 DR650 with 6k miles on it. It runs pretty bad at low speeds and wants to stall if it’s not supplied with ample throttle. It seems fine once brought into second gear and ridden faster. I suspected most of the problems were because of some carburetor mods.

Here's how my brother described it:

Here are all the modifications I have identified:

Carburetor modifications

1. Slide spring cut/shortened
2. Slide drilled with an additional hole
3. White plastic needle spacer modified into a D-shape
4. 152.5 main jet installed
5. Jet needle tip appears to have been shaved/ground down

Intake / exhaust modifications

1. Stock air box snorkel removed
2. Two additional holes cut into the air box
3. Lexx MXe exhaust installed (the quiet core insert is broken and moving in and out)
4. 14T front sprocket

My plan is to try to return it to as close to stock as possible. So, new needle, 140 main jet, new spring, new slide, and new plastic needle spacer. I’m not sure if I should worry about the air box and exhaust. I suppose I can always patch the air box if needed. Should I change everything back to stock, or are some things fine to keep, like the exhaust? thanks

It's a 1993 Suzuki DR 650 R, with kickstart. It's my first A2 bike, and my first kickstarter, and I LOVE every inch of this thing, from the kickstart, to the pops of the exhaust. It has a Dominator exhaust, and is LOUD.

Hey guys, had a few concerns when doing the Procycle NSU safety wire kit.

1. When taking out and reinstalling the 2 screws that hold the plate in front of the NSU (The breather cover shown in the 2nd photo) I slightly mushed/half-striped the heads of the screws from using Philips and not JIS. I screwed them down pretty well but im wondering: should I have added some kind of Loctite on those? Is it worth it for me to remove the clutch again and replace the slightly mushed screws?

2. Having a hard time removing the old gasket; what do you guys use to help with this?

3. I know the safety wire doesn't look pretty, but will it hold ok?

Please share your experience, thank you!

Seller is asking 2800 (negotiable), I did some research and landed on owning a DR650SE >1996. What do you think about the price and condition? What would you think is a fair price for its condition?

1996 model, 60k 50k kilometers.

Found this plastic 'fluid reservoir'? Behind the rear shock. Any idea and if the black debris is a bad sign?

Found a short on my dr650 ignition. Will this be ok to heat shrink without replacing the wire? Never have had a short before. Is the wire bad?

Finally decided to get around to the suspension. Got this bad Larry off marketplace and just ordered the cogent DDC fork kit. Very excited to piece this fat pig together

I didn't know about these wear items until I had problems with the middle of my throttle.

Slide has worn through the wear marks, needle jet has a decent wear mark half way down the bore, explains the bogging I was getting at mid throttle.

A friendly reminder to the new mechanics to check these when you clean your carb, before it wears into the needle jet.

I have a 2023 Suzuki DR650 that I bought used with only about 1,400 km. As far as I know, the clutch had never been opened.

I recently found a significant amount of fine black powder/grit with some shiny metallic particles in the oil filter.

I also had a symptom where, at around 110–120 km/h, the engine would get loud/high in RPM but the bike didn’t seem to pull as strongly as expected. I wasn’t sure whether this was normal DR650 behavior, fueling, or clutch slip.

Then on one ride, after riding all day, I was in 5th gear and accidentally released the clutch thinking I was shifting into 5th. The RPM suddenly flared and the bike felt almost like it was in neutral for a couple of seconds, then it engaged normally again.

I opened the clutch and found that the friction plates are burnt/worn. The last friction plate looks good and measures within spec.

The interesting part is that all 8 original OEM friction plates appear physically identical. And the same number stamped on them. The clutch has never been opened before, so these are presumably the factory-installed plates.
I have purchased:
7 new friction plates (thinking that the 8th is different and i couldn’t find it where i live)
8 new steel plates
The new steel set contains 7 identical plates and 1 different/thicker plate.

My questions are:
Is it normal for the original 2023 DR650 to have all 8 friction plates looking identical?

If one of the original friction plates is still within specification and undamaged, is it reasonable to reuse it with the 7 new friction plates?
If so, does the reusable friction plate need to go in a specific position, or can it go anywhere in the stack?

Is there anything else I should inspect before installing the new clutch?

Hello,
I’m writing with a question about a 1994 DR650R. I’m replacing the clutch kit and have run into a few uncertainties.

The engine is the 640cm3

The old clutch had 7 friction plates (1 thicker) and 6 steel plates (1 thicker). The new kit has 7 friction plates (1 thicker) and 6 steel plates (none thicker).

Also, when I disassembled the clutch, there were no washers, even though according to YouTube videos and the documentation, it looks like there should be several.

So my questions are:
Does it matter that one of the new steel plates is thinner than the old one?

How many washers are supposed to be there? Is it possible for there to be none?

The old clutch was slipping quite badly, especially in the higher gears. Could the missing washers have been the cause of this?
I’ve attached photos of the old plates.

My new clutch kit: https://www.motopulsas.lt/detales/dr650r-dr650re-dr650rs-1990-1995m-sankabos-komplektas-ebc-drc059-std.html
Maybe someone has installed this kit before and knows the answer?

According to the technical diagram, my old clutch was missing washers #5, #11, and #12.

Thank you for the help!

The first friction plate is worn out completely. Should i replace the pressure plate as well as it has grooves and scratches. And also, there is a steel plate at the end as you can see in the last photo, that is held down with a wire, should it be replaced as well?