SUZUKI DR 650 S 1992        

Rider Weight in Kilograms:

Ideal Fork Rate: kg/mm

Ideal Shock Rate: kg/mm


Stock Fork Spring Rate: 0.400 Progressive

Stock Shock Spring Rate: 6.00 kg/mm


Trail


Ideal Rider Weight 55 kg


4 Stroke Engine 650 cc


Shock Preload Collar Spanner

Shock Preload Collar Spanner

93-015-00

$28.60

Shock Oil/Dust Seal Set 14x26x5mm Showa

Shock Oil/Dust Seal Set 14x26x5mm Showa

22-410-00

$35.00

Shock Oil Seal 14x26x5

Shock Oil Seal 14x26x5

22-409-00

$25.00

Shock Dust Seal Showa 14 x 22 mm

Shock Dust Seal Showa 14 x 22 mm

22-417-01

$25.00

41mm id x 53mm od x 7.5mm height - KYB Conv

41mm id x 53mm od x 7.5mm height - KYB Conv

24-840-00

$55.00

20-051 Motorcycle Shock Spring
RRP $218.90
19-080 Motorcycle Fork Springs
RRP $218.90

Specials!
We have been running a DR650 suspension special with the ADV Rider forum for a while, and it's hugely popular! We like the DR and it's workhorse like nature. Our aim is always maximum performance at minimum cost, so we offer these special prices for the following packages only:


Stage 1.
New Fork Springs, V4s Valves in Forks, Damper Rod Modifications. Revalved Stock KYB Shock, New Shock Spring.
We have put so much development into the stock KYB shock we give you a money back guarantee against any other shock. If you ride another DR with a better shock than our modified stock DR shock bring us your DR shock back and we will turn it back to stock and give you a refund.

Suspension Only $950
Ride In & Ride Out $1100

Stage 2. New Fork Springs, V4s Valves in Forks, Damper Rod Modifications. Yacugar shock 21.29.154 . This shock offers amazing performance, similar to our modified stock shock plus rebound adjustment. We were very surprised when we ran it on the shock dyno at how good it is. It comes with a 7.5kg/mm spring suitable for up to 100kg

Suspension Only $1395
Ride In & Ride Out $1550

Stage 3. New Fork Springs, V4s Valves in Forks, Damper Rod Modifications. Ohlins Shock (SU602).

Suspension Only $1995
Ride In & Ride Out $2095

Every option is sprung front and back to suit you and your application. Every shock option is dyno tested on our suspension dyno to ensure it meets our standards. No matter what you use a DR650 for, we will supply a package that works!




"The best suspension of any bike i've ever had, it's awesome"- Terry 29/9/15

In 2014 we had some great feedback from a good customer, "Unrideable, bottoms everywhere, washes out in sand". The customer wanted to use his DR as an RMX450 and ride it on enduro loops, adventure riding and the odd MX track with his kids. While this was outside what a DR is made for, it reminded me of modifying trailbikes to race in Thumper Nats in the 90's. While we had never done this kind of development to a DR it was too tempting to pass up.
The next 2 weeks were spent pulling forks and shocks in and out, trying some recommended parts like Race Tech's adjustable rebound for the shock, the CD Moab shock and the SuperBrace. We did most of the testing at a track 10 minutes from the shop that's a notorious whooped out sand track with a hard pack clay base next to it. What we ended up with after 600km and two weeks was settings that we are very happy with. The testing was done by our resident B Grade MX rider who has a lot of trail miles under his belt. He came away slightly astonished at how good the DR can be. The best part is it's still great on trails at low speeds. It's exactly what we wanted, an even better setting for our customers on DR's while retaining the low cost fun factor that makes the DR a favourite. We affectionately call it the "Giblett setting" After its instigator, Rod Giblett. It works even better than what were using before.

"I have had this package installed by Nick and I cannot believe the difference it has made. Highly recommend this to anyone, especially if you haven't got a PhD in suspensions or the time and patience to research on the Internet (unlike some on this and other forums). Go see Nick, tell him what sort of riding you do, and he will get you sorted with a minimum of fuss and hassle free & too bloody easy. You will not regret it."
- John Morasutti
Forks
Early model DR650's (1990-1995) used 41mm Forks, while 1996 on DR650's used 43mm Forks, both of them Kayaba Conventional units. There are differences, but both are very similar in terms of the way they work, so they end up getting the same kinds of tuning. And we stock a pretty darn big array of spring rates for both forks.
We also modify the damper rods and fit our V4s valve (our version of a Race Tech Emulator, PD Valve, Travel Control Valve, whatever you want to call it), it gives a speed sensitive dampening character to the damper rod fork. Like many of our parts it's made here in Australia. We have a lot of very happy customers running around OZ on this set-up, it's robust and well priced.
  • Fork Revalve & Service with V4S Valves. For either the later 43mm or earlier 41mm Forks, we do the same types of mods. You can also find the fork spring rate you need HERE.

    New Fork Springs Approx $200

Shock - Non-Rebuildable - 1990-1995
The earlier DR had a non-rebuildable rear shock. What we can do is turn the shock into a rebuildable unit, which makes it easier (and cheaper) to Service in the future.
  • Non Rebuildable Shock Overhaul. We modify the original shock case with a gas port, replace the seals and put it all back together, giving it a 12 month warranty. Be aware that if your shock shaft isn't that good, it may need a re-chrome to make sure the pitted old shaft doesn't tear up the fancy new seals, and this costs extra.

    Shock Shaft Re-Chroming $

Shock - 40mm KYB - 1996 on
Not as bad as the forks but it can't cope with any weight, the stock spring is really light and the dampening is minimal. The shock is a 40mm KYB unit, compression adjustable only. While it's not the "trickest" shock out there it's a very reliable unit and easy to service and modify.
We have used complete shaft assemblies with pistons, Gold Valves and the like but it adds to the cost. After a lot of testing, both in the shop on the shock dyno and with selected mad bastard customers, we have a shock setting that makes whoops out of Finke manageable, does not beat you up on an 800km day and makes the DR a whole lot more fun to ride. This revalve uses the original piston, and we think it beats the stuffing out of the American Race Tech piston. We don't make the rebound adjustable as we don't think it's required and just adds to the cost. As the great Laurie Alderton said, "You don't need 40 clicks of adjustment; you only need one, the one that works!" Ours works. No gadgets.
We couple our shock mod up with a spring specially made for the DR650, so no spacer is required (unlike our competitors) and you get plenty of preload adjustment.
  • KYB Shock Revalve & Service. We repair, rebuild and revalve your stock Kayaba shock to suit your riding and your weight. Find the rate you need for our DR650 specific springs HERE.

    New Shock Spring Approx $200


*Pricing based on a new or as new bike. If you need consumables, seals, bushes, bumper, shock seal, shock shaft, you need to pay for these consumable parts. The service won't cost you more as we already have the suspension apart.
Pricing does not include freight to and from our workshop. We use AusPost, TNT and Toll. almost anywhere in Australia is $25-35 one way, road freight.

Extra Options

  • DRZ400 Suspension Conversion Advice. Some riders swap out the forks for DRZ400 units, but the triple clamps have to be swapped as well, because the fork size is 49mm. You need to run the 400 wheel too, as the axle is bigger, or make up a custom axle and spacers. After all that, the DRZ's fork springs are only 0.44'skg/mm, far too soft for most people, so you end up spending more money on harder fork springs. The stock 650 disc is bigger than the 400 too.
    The DRZ400's shock is better, being a 50mm Showa. It needs quite a lot of reworking to the linkage knuckle on the 650 as it's narrower, requiring milling and a bearing that's not easy to get. Added to this, the spring series is different on the DRZ400 shock, so the stiffest spring we regularly stock is a 6.8kg/mm (20-115-68). Plus the shock needs a revalve to be as good as our modified stock DR650 shock. The advantages are that you have are a rebound adjuster and more oil capacity.
    Think very carefully about what you want to achieve before diving in.
  • Gearing. The stock 15/41 is too tall for any normal purpose. For anyone the bike works better with a 44 tooth rear, available from Vince Strang Motorcycles.
  • Tyres. We don't love the Pirelli Scorpion MT 21's on the DR. In fact, we don't like the MT21's on about anything! The Michelin HP4 front in a 90/100 is great, but not road legal. The rear Dunlop D606's are OK. For a big distance rear try the Heidenau K60 Scout rear.


41mm OD

Kayaba (KYB) Conventional 41mm OD


External

Top Out Type External


240 mm

Fork Travel 240 mm


37.9 mm

Fork Tube Inner Diameter 37.9 mm


35 mm

Front Sag 35 mm


4.0

Emulator Preload Turns 4.0


64 N

Emulator Spring 64 N


41mm id x 20mm height x 1.0mm thick

Inner Bush Dimensions 41mm id x 20mm height x 1.0mm thick


41mm od x 12mm height x 2.0mm thick

Outer Bush Dimensions 41mm od x 12mm height x 2.0mm thick


36.5 mm

Fork Spring Large Outer Diameter 36.5 mm


36.3 mm

Fork Spring Small Outer Diameter 36.3 mm


52.6

Number of Coils 52.6


17

Spring Coils Progression 17


553 mm

Spring Free Length 553 mm


0.400 Progressive

Spring Rate - Measured 0.400 Progressive


42 mm

Spring Spacer Length 42 mm


4.90 mm

Spring Wire Diameter 4.90 mm


574 mm

Set Length 574 mm


7.5

Fork Oil Weight 7.5


130 mm

Fork Oil Level 130 mm


2 Litres

Oil Quantity 2 Litres


40mm ID

Showa 40mm ID


Yes

Shock Linkage Yes


175 psi

Nitrogen Pressure 175 psi


5 Weight

Shock Oil 5 Weight


14 mm

Shock Shaft Outer Diameter 14 mm


12 mm

Shock Shaft Outer Diameter at Valve 12 mm


M12 x 1.25

Shock Shaft Nut Thread M12 x 1.25


#44 (2.2mm)

Shock Piston Rebound Bleed #44 (2.2mm)


85 mm

Standard Sag 85 mm


25 ft lbs (34 NM)

Shaft Nut Torque 25 ft lbs (34 NM)


256 mm

Spring Free Length 256 mm


59.0 mm

Shock Spring Large Inner Diameter 59.0 mm


55.0 mm

Shock Spring Small Inner Diameter 55.0 mm


6.00 kg/mm

Spring Rate - Measured 6.00 kg/mm


0.0006

Slope of Spring Formula 0.0006


0.36

Y Intercept of Spring Formula 0.36