This is a collection of FAQs for Suzuki DR 650. Please send in suggestions for additions or changes. Mods – please sticky this in DR forum! If this does not prove useful, we’ll kill it.
The links provided from here are from various sources. Can’t promise that everything will be up when you look for it! Many link to DR650 Wikia, as there is a ton of info there, but I figured people don’t know about it always. I have saved several things in PDF format because pictures on forums are known to disappear over time.
NOTE: It is completely possible that not the best thread or page about the specific subject is linked to in this FAQ draft. If so – please don’t get ticked off but rather PM me and I’ll fix/add stuff! This FAQ will rock if we all make it rock!
NOTE 2: Huge thanks obviously goes to people that contributed to threads and pages that I link to. Props to all of you!
- Exhaust page on DR650 Wikia
- Header polishing
- Header weld grinding
- How to repack your FMF-Q2 silencer(by mx_rob)
- Intake page on DR650 Wikia
- (please send me more links)
- Windscreen page on DR650 Wikia
- Various windscreen advice threads: Turbo City and various options discussed
Guarding and Protection (skid plates, crash bars)
- Lighting page on DR650 Wikia
- Buell headlight mod
- Some 100W light bulb information
- Trailtech HIDs
- Where to connect accessory lights
- Brighten up your turning signals cheap
- Tail light conversion
- Suspension page on DR650 Wikia
- Cogent Dynamics suspension and brake upgrades
- How to make your own damper rod tool
- Save $$$, Replace Your Own Fork Seals
- Installing a DRZ shock into your DR
Carb work and carb tuning (jetting)
- Tuning the 39mmFCR
- Tuning Mikuni tm 40
- DR650SE Needle Comparison (an epic thread by mx_rob)
- How to do simple carb mods (step by step),PDF with pictures is here
- The BST-40 Bible (by laramie LC4 on advrider) – stock carb. PDF with pictures is here
- Basics on carb adjustments
- How to change oil
- How to adjust valves. PDF file with photos here.
- Chain maintenance and lubrication (no lack of opinions on this!)
- Is your chain too loose/tight?
- Electrical page on DR650 Wikia
- DR650 generator capacity test results
- Kick Stand Safety Switch (and how to bypass it)
Drive / gearing
- Drive page on DR650 Wikia (includes 520 conversion and 525 options)
- How to change the counter sprocket ( CS ) / front sprocket. PDF version with photos here.
Common (and not so common) problems
- Surging / cutting out issues: read this, thisor this
- NSU (neutral sensor unit) screw backing out: read thisand this
- Upper chain roller breaking off: read thisand this. Already broke off? Read this.
- Fixing cam chain tensioner gasket leak
- Base gasket leak (typically 2003 and earlier): read this, thisand this, and then search some more... lots of threads on this.