Our DR650 Introduction and Build Update

This is a little introduction to our DR650 and an update of restoration and parts upgrades that have been done to the bike over this winter. Plus, a little ride to and through the Shotgun OHV trail system near our shop.
If you are in need of parts for your DR650, checkout our website at: procycle.us/mo...
Or if you need some help figuring out what parts you need for your dual sport or adventure bike, give us a call at 541-688-9543
We are open Mon-Fri 9:30AM - 5:00PM PST
Instagram: www.instagram....
Facebook: / procycle.us
Website: procycle.us/
Newsletter Sign up: procycle.us9.l...

[@tarjas]

Can never have enough DR650 content. My beer fridge is almost covered with Procycle stickers!

[@Adventurebean541]

The mighty yellow swing arm sticker😂

[@TeamProCycle]

We feel the same way! Rumor has it, if you have enough stickers on your fridge, it will be more insulated. Resulting in a smaller power bill allowing you to buy more parts for your bike, haha.

[@rockenjoshy]

You can't have a DR650 without Procycle, thank you!

[@TeamProCycle]

Right!? We just had to get one back in the shop again. Thank you for watching the video!

[@TheAnnoyingBoss]

Its just wild to me how i can buy 30 year old suzuki engineering in 2023 basically unchanged but i cant get a 1990 accord in 2023

[@TeamProCycle]

It is pretty wild and those old Hondas were one of Hondas better looking Accords. I miss the skinny wide lensed head lights.

[@oliverjackson2594]

Amen to this, procycle rules

[@doc650adventures]

This is great! Love how you have built your Mighty DR650! The product support you guys provide for the DR650 is off the charts amazing!! Most of the mods I have done to my DR came from you guys. Looking forward to seeing more content on this DR650! Cheers guys!!

[@TeamProCycle]

Thank you! We sure do love the DR around here, haha. Cheers!

[@PennsylvaniaDualSport]

Hi Doc 🐷

[@doc650adventures]

@@PennsylvaniaDualSport Hey Matt! Cheers!

[@sumo_steve45]

Lake City, Florida and the whole DR650 community LOVES ProCycle !!!! Huuuuuge thanks to my friends Lora and Mike ( and the rest of the Team ) that keep us all supplied with awesome parts and phenomenal customer service. Now if I can just get that darned TM42 to work right on my DR650. ( sigh ) I digress, the product/s that come from this business - whether physical or otherwise are literally the best in the business!!! Thank you all soooo much for what you do. Steve Ashe

[@TeamProCycle]

Thank you for the kind words, Steve and we appreciate the support you have shown over the years and assisting everyone in the dual sport community. We do our best to help everyone out equally, but it's customers such as yourself that really help make everything workout the way that it should be.

[@bradsanders6954]

There are droves of people with DR's, trying to get their new carb/cut airbox/trick exhaust to all jive together. Some carbs have ultra stiff throttle pull, some get crap mileage, some people say "it works great!" when it really doesnt. Its kind of like hopping up a Station wagon. Its still a station wagon when your done.

[@modshiftmotion]

Nice. I bought my header, muffler, intake, jet kit, and more from you guys. Thanks for all the parts!

[@TeamProCycle]

That's a great combination to get any bike running right and thank you for your business!

[@littleDoughie]

Your videos are fantastic my guy!

[@modshiftmotion]

@@littleDoughie Thanks brotha!

[@Adventurebean541]

Gotta love a 90's thumper!🎉🤘🏻😎

[@coleneville3073]

My dr650 is a whole other animal thanks to procycle. Best money ive ever spent.

[@TeamProCycle]

Thank you and we're glad to have helped your DR change into the animal it is today!

[@Sarj_ent]

I would love to see more content about the 790 upgrade. Not much info/reviews out there from people who've made the leap and my wallet doesn't need much convincing. Those mirrors look great on there and actually reach out past your elbow

[@TeamProCycle]

Thank you for the comment, we will try to get some more content out in regard to the 790 upgrade. Surprisingly to myself, the mirrors work really well for riding in traffic. I can see a lot around me and unlike the other mirror, they stay where I position them, haha.

[@andrewmcglynn4107]

Also interested in 790 content. Subscribed! 👍

[@timsilva1944]

Procycle has relieved more of my money than I care to admit. Carl and Mike are always helpful. Very similar to my DR build. The kill switch is a common fail point. They tend to stick in the off position, leaving you frustrated. I modified mine to be a momentary button like a dirt bike should.

[@TeamProCycle]

Thank you for the kind words. I know Mike and Carl appreciate it and are hard workers. The kill switch probably faced the same fate as others and failed leaving the previous owner to resort to customizing the switch. At the moment I'm trying to decide on whether I should go with an OE replacement or do something a little different. Decisions.. decisions.. haha

[@bradsanders6954]

Some good stuff on your bike, some is just bling some is good stuff. The magnesium hubs and bars are magnesium colored anodizing over aluminum. Ive got 51,500 miles on my 2003 DR 650 and it has yet to burn any oil or need anything done to the engine, and it has been cruised at 85mph on road for hours at a time. It runs smoother at that speed than it does at 75mph. Stock gearing. Ive done the suspension, Cogent is great on the back, race tech gold valves and springs in front, good knobbies are ran. The Tusk knobbies are pretty good. Ive raced flattrack a lot, and some MX on real dirtbikes, Ive pushed the DR pretty hard and learned it's limits. The frame is the limiter, no matter whats done to suspension that frame will kill you at a certain point. The flexing and wallowing and wobbling it can do can be really scary. But it has to be pushed hard for this to become very evident. In a straight line its more or less ok but broadsliding it can go south pretty quick..............once the wallow starts it wont stop. I can still go pretty darn fast on it, but the limits need to be observed, or hospital time could be near. In general the DR works way better than most folks think it does.

[@lilliboo9427]

The details are great! Makes it much easier to understand.😀

[@TeamProCycle]

Glad you think so!

[@T30-z5w]

Miss my DR. Had it for many years. Rode the hell out of it, 55k miles. I sold it when I upgraded to a new KTM690. Love the 690 too but it’s a different animal with different character.

[@TeamProCycle]

55k miles of pure enjoyment I bet, and you're right, the 690 is a different animal. In comparison, the DR is more of an ADV / dual sport bike where the 690 is more of a dual sport / enduro bike, two completely different worlds of riding. I know that you're probably having a blast on that 690 though.

[@johnpeters6887]

I bought a new DR650 last year (2022). Thanks for the video. I appreciate everybody at procycle. I lust enviously after that motoz adventure rear tire you're showing off in the video. I'll be back to grab one after I get a few more miles on my stocker. Among other goodies. Thanks again procycle! And great video!

[@TeamProCycle]

Congrats on the new bike! The Motoz ADV tire continues to surprise me as I try to put it through different terrains and riding styles. The tire just works! Thank you for the kind words and doing business with us, it's customers like you that make us work harder and enjoy what we do.

[@mcrcowboy]

Hello from Mike in Sacramento with 2 DR650's. Cousin to John the Rack Man. Great Content. Thanks for your help with my rides.

[@TeamProCycle]

Hello Mike! Glad we have been able to help you with your DR's and thank you for the kind words, and for supporting our small business!

[@xsailor1970]

Dr’s are awesome! We are looking forward to more content. We just have a DRZ right now but are looking to add a 650 and maybe even a 350 too. Been checking out your website like a kid from the 70’s with their Sear catalog!

[@TeamProCycle]

Having the DR650 and a DRZ in your garage is a great combo to have. You just some of us back in time with the Sears catalog comment, haha! Thank you!

[@scotscottscottt]

Purple, orange and blue... interesting choice...

[@TeamProCycle]

People remember the different things in life. Haha

[@PSBEadventures]

Awesome! Koty and I both have the acerbis tanks on the DRs. It sure has helped us pass a few more gas stations and venture out further. Thanks for the video. I bet that big bore makes her rip!

[@TeamProCycle]

Glad you were able to get one on your bikes. They truly do help get you out a lot further on the trail with out worry of running out of fuel. The 790 kit really woke the bike up and increased power everywhere in the rev range. I'd say the power is now suitable for the weight of the bike, before it was leaving a little more to be desired in its stock forum.

[@SB-fe4gt]

Great video...thanks for covering everything :)!

[@TeamProCycle]

You're welcome, and thanks for watching!

[@bradsanders6954]

As we all know by now, for what it costs to make a DR really cool, a 500 KTM could be had. If you really want a full dirt dual sport like most seem to want. The KTM isnt really any good on the road though. A 690 or 701 could be neat, kind of an acquired taste . Some spend 5K on DR mods, they are solid bikes, very solid.

[@JC-gj1gg]

Yes all true but ktm maintenance schedules and reliability are concerns when you are relying on a machine to get you where you want to go with little to no issues. Mods choices galore too

[@screamingoreo]

Thank you I just bought one 😊 you guys are the dr gurus

[@TeamProCycle]

Thank you! And congratulations on getting a new bike, if you ever need parts or assistance with anything reach out to us.

[@gmmq6882]

Holy crap! $20,000 bike!

[@TeamProCycle]

It looks like it, but it's not quite there. Haha

[@bradsanders6954]

Not the one in this posting, but some DR's are near that level for sure. Once you start spending there's no end of things to "fix" on a DR. Like hopping up a station wagon. At end of day it needs a real frame, just keep the engine.

[@zacsmith814]

Great content!!!

[@TeamProCycle]

Thank you! We are trying to give the best content we can, it's all a learning curve for us.

[@gleaminthecube5664]

Dang, that bike sounds nice. Dear Procycle, I saw your video and am now saving money for the 790 kit, a bigger cam thing, oversized valves, a pumper carp and orange tube caps. Not that I'd know what to do with any of it.

[@TeamProCycle]

Thank you for the kind words and that would be one awesome upgrade to your DR650! Installation of the pumper carb and orange tube caps are pretty easy to install for anyone. If you do the cam and big valve head, we do recommend a professional install them for you. The big bore kit can be installed without a mechanic if you have good mechanical aptitude.

[@tenciodg]

I like the color combination, really cool!

[@TeamProCycle]

Glad you like it and thank you!

[@Adventurebean541]

Agreed. It's something different for sure!

[@barsandrunning]

05 yellow Dr , want to paint frame Suzuki purple to go with Suzuki yellow sick bike Dr 650 u have to take everything off paint frame.guess fml one day maybe

[@tracythorleifson]

Thanks for the great video! You guys have made my old DR very happy over the years! I would love to see more content on the 790 upgrade (and the wide ratio gear set, that matter). I told myself I’m going to wait for the head gasket to let go before I pull the trigger on the big bore kit, but now it’s 10K miles later, and I’m getting antsy. The ol’ pig is just too reliable. You guys need to give me an excuse to just buy it! 😂

[@TeamProCycle]

Thank you and we're glad to have been able to help you over the years. We are working on getting some more DR content going and eventually the wide ratio transmission will be up for install. The DR is a very stubborn bike in the regards to it never wanting to die but, if you need a reason to go 790 big bore, I can think of 140 reasons why. Haha

[@rupertsuzuki3376]

Great video, great looking bike…do more of them please. Add another check mark for people wanting more 790/wide ratio content. Not install (although that would be good too) but pro/cons, living with it and day to day changes they made (range/reliability/how temperamental/driveability/value/etc). I’m stalled because I can’t see doing the BBK without upgrading the gearbox and clutch and when you add the items up it’s the cost of another DR. At least I already have the carb and header… So I need to build a case for the expense and scope of work…do these two changes and there isn’t any going back (easily) plus it would drain the toy fund for some time limiting options if it didn’t meet expectations… After a gearbox video (please) maybe a comparison video; stock vs modded vs T7/690 (or similar).

[@bradsanders6954]

The only thing is, dont test ride a 701 Husky, or a 690 KTM. 73 HP stock with more to be had. Yeah its not a Suzuki......but one ride will ruin anyone who wants more power and real suspension and frame/wheels/etc.

[@lluis9377]

Great build!!

[@TeamProCycle]

Thank you! B sure to stick around as we will be releasing more DR650 videos soon.

[@PattyintheWoods]

More info on that dash mod would be nice! Love it

[@TeamProCycle]

If you're interested in getting one of these dashes for your DR650. We have them available on our website. Follow this link to check it out: procycle.us/product/2290

[@olsonjslipknot]

Nice upgrades 😮

[@TeamProCycle]

Thanks! 👍

[@davidlipschitz6422]

Sweet sweet bike!

[@TeamProCycle]

Thank you!

[@holisticaustralia]

Very Nice! Well done 👍

[@TeamProCycle]

Thank you!

[@telcobilly]

I miss my 2003 DR650! I had a 1993 as well, not nearly as good as the 1997+ id buy another, but no DR650s that I know of in the Philippines..

[@TeamProCycle]

That's unfortunate, you can't get your hands on a DR there. Maybe one day there'll be a way for you to reunite with a DR650 again.

[@JS-lv5pn]

Back shock do good with just the spring upgrade?

[@hirdy161]

Urgh I want a DR650 so bad. Can't get them here in the UK. 😪

[@TeamProCycle]

That's unfortunate you can't get them new anymore. I did stumble across these guys in the UK that have a used one available, might be worth a try: kzbin.info/www/bejne/fInOYoWdfr-Bp80

[@PennsylvaniaDualSport]

People don’t believe me when I say you can get a conventional fork to perform well. Besides having the Cogent treatment I’ve played around with air gaps to get it just about perfect. Me and clickers don’t get along. The forks on my fancy Italian princess Beta will tell you.. “ all he does is molest me with that flathead screwdriver.. turning this and turning that. Sometimes multiple times on every ride..”😂. I got a good list on my DR however still rocking the modded BST. Actually thinking of trying a smart carb out.

[@TeamProCycle]

Haha, your Beta comment is killing me! It's hard to think of a damper rod system being able to perform with a cartridge style fork but, it is possible. Granted if you're out pounding whoops and doubles at high speeds, the cartridge will eventually win but, how many riders are actually riding their bikes as if they're in the Dakar rally... There's nothing wrong with rocking the BST but, upgrading your carb does make a huge improvement in overall rideability.

[@samiam247]

Do you have a dyno graph for the procycle stainless header pipe?

[@TeamProCycle]

We do not have a dyno run to show for the new headpipe. Maybe one day we will be able to get something together.

[@Pmz604]

for the long distance tourers , I'm curious based on the current modifications/setup..whats the approx fuel mileage like?

[@TeamProCycle]

With this setup mixed with the way I ride and terrain we have here. I can get a little over 200 miles. If I lean the jetting out some more ( which I probably need to) economy will go up. Plus, I'm running the stock gearing and ridding a fair amount of freeway riding. So, that doesn't help much. I may experiment with a 16T sprocket for a little bit to compare fuel economy as this question gets asked often.

[@davidrivera1727]

Did you say you’re running the stock gearing 15-42? Let me know.thanks

[@TeamProCycle]

Yes, the DR has 15 /42 gearing and was converted over to the 520 setup.

[@davidrivera1727]

@@TeamProCycle what is the benefit of going to 520 chain?

[@TeamProCycle]

The 520 chain and sprocket setup is lighter than the 525 setup and is more readily available around the world, with more options to choose from i.e., Sprocket materials, chain seal types, chain & sprocket colors. The 520 components can also be found a little cheaper than the 525.

[@bradsanders6954]

@@davidrivera1727 520 doesnt last as long, Ive tried it a few times. 10,000 miles is a long ways for a 520 kit. Ive got 50,500 miles on my DR so Ive tried different thing. The 525 goes longer for sure. Ive never had trouble finding the 520 kit to install, I get a few extra master links but the rivet master links work great and dont come apart.

[@hegemonictrader45]

Can you link me for the black wheels? Do I need to do anything special going to 18” rear wheel? I have a ‘23 DR650

[@TeamProCycle]

Congrats on getting a new DR650! Here is the link to our rear wheel builder: procycle.us/product/1800 Give us a call, we can get you a new 18" wheel going if you don't find what you're looking for. If you go with an 18" rear, be mindful of the tire width you go with. There is limited space in the swingarm to allow a 140 or larger tire. Also, be mindful that this setup makes for a taller tire setup, raising the bike up higher. The increase in height is subject to what tire you choose, as not all tire sizes are equal amongst manufacturers. Thank you for the great question.

[@MoBessiere]

I am new to the whole Adventure/duel sport thing and having a blast. Right know I am running a 130/90-17. What are the advantages of running a 18 rear.

[@jensenmiller6410]

More options for dirt tires and you gain some ground clearance, if you are a mostly road going rider then stick with the 17. It's best to balance the 18" rear with some taller front tires to keep your trail geometry comfortable.

[@TeamProCycle]

What @jensenmiller6410 said is correct. Plus, going over obstacles is a little more manageable compared to a 17" wheel. Depending on how this year goes, the DR may end up in some scrambles and I want a good selection of tires to choose from.

[@bbevis2357]

Any concerns about the potential 3rd gear failure with the 790 kit?

[@TeamProCycle]

No, at the moment I don't get a chance to ride enough to make a difference, haha. In all seriousness though, the 790 kit can add to the potential of a 3rd gear failure but, we don't believe it to be a big enough difference to warrant any need to stress over the idea. It's more of a rare circumstance and a stock DR650 can suffer from the failure. If you stick with regular maintenance and use a magnetic drain plug, you are likely to catch anything going wrong before something major goes wrong. We have seen more issues with NSU screws than any 3rd gear issues over the years. We offer the updated gear set for those that have experienced it and insurance for those that haven't. With that all being said, eventually a wide ratio gear set from Nova will be going into the bike. Sorry for the winded response but, I hope that better answered your question.

[@bradsanders6954]

@@TeamProCycle If the wide ratio set is stronger it could be good, but Ive done a lot of 85mph cruising on my stock geared DR. It seems most DR owners havent tried this? The thing runs smoother at 85 than it does at 75. How wide a ratio do the gears need to be?

[@c_schafe5347]

I can’t seem to find those turn signals where did you get them?

[@TeamProCycle]

They are made by Cyclops Lighting. Unfortunately, they are not making anymore at the moment but, we do offer a similar functioning turn signal: procycle.us/product/2939 We are trying to get the Cyclops turn signals back as they are a very popular upgrade.

[@used2befast]

For the shock, did you only install a stiffer spring? No internal mods?

[@TeamProCycle]

For the rear shock I was able to swap in a brand new (pretty much new) OEM shock and then swapped a heavier spring for the stock spring, no internal mods were done. I want to play around with this setup for a moment before switching to a new complete assembly shock from Nitron or Cogent and for what the riding I'm doing right now, it works perfectly.

[@bradsanders6954]

The stock shock is garbage, if you mod it, it overheats and wrecks itself. The damping is non existant and is even worse when it gets hot. Its a pogo stick and worse with stiffer spring, no damping to speak of. I tried race tech mods and it never worked, even with 3 revalves by a race tech guy. The Cogent shock was great right outta the box. Some cant tell the difference one way or the other, they just want a loud exhaust.

[@prhannator2874]

I got the 2021 new oct 2021. It sounds like you converted a DR into not a DR lol. What would that cost someone who doesnt work at a shop? More realistically, what is a tried and true way to gain some low end grunt without ruining reliability. dont find theres much throttle response availble when trying to pop the front wheel up. Ik also new to off road machines and was never a wheelie or tricks guy. Tips? Is it just practice bone stock or a big payout in upgrades? Great build.

[@TeamProCycle]

Hello and thank you for the great question. We get this one a lot, and you don't have to throw the book at your DR for it to look great or perform amazingly. If you're wanting to maintain reliability and gain low end grunt, you have two impactful options to choose from. First, upgrading to a TM40 is going to be a game changer in performance. The accelerator pump will give you the low end boost most DR riders are looking for. Next, changing you're sprocket sizes can help give the low-end grunt you're looking for at a fraction of the price. As for popping wheels.. practice, practice, and more practice.

[@bradsanders6954]

The stock DR gearing is a major hold back to popping the front end up, just a smaller countershaft sprocket helps a lot, some lower the gearing front and rear. The bike doesnt lack that bad on low end grunt, but its geared really tall. I can go 45 mph in 2nd gear with stock gearing. The carb swap isnt THAT simple nor is it that cheap.

[@amelica5502]

What did you mean when you said the 790 kit is not for everyone? What are the downsides? Vibration worse or an issue especially on the highway at 75 or 80 mph? How about Cooling in the desert Southwest? I'm looking to use mine for dual sport and trail riding with sometimes extended highway riding with a passenger and camping gear, and be able to keep up with traffic and handle some headwinds if they pop up All up load expected to be around 300 to 380 lbs with passenger and gear

[@TeamProCycle]

What mean by "it's not for everyone" is that some riders feel the DR has enough power and is super reliable in its stock form. When ever you start adding power mods to any engine reliability begins to decrease. Not to say that the 790 kit makes the DR unreliable but, there is that trade off. We have customers with 10s of thousands of miles on their 790 kits with no issues at all. There is a slight increase in vibration but, nothing that would make it unbearable. The cooling fins and OEM oil cooler combined work exceptionally well at keeping the DR temps regulated. If you find yourself riding often in a hot environment at slow speeds, working the clutch often and demanding a lot from the engine. Then the 790 kit will increase the engine temps. It should never reach a point of over-heating due to the factory cooling system in place. So, more frequent oil changes can help combat any negative effects that style of riding can impose on the engine. Also, adding a Maier oil cooler air scoop will really help and even just backing off the throttle and cruising for a little bit will cool the engine back down. The 790 kit will give the DR plenty of power all across the rev range to accommodate highway riding with a passenger and gear. I've ridden two-up on my DR790 on the highway and have had zero issues moving along in traffic or even keeping up with traffic for that matter. Head winds will be no problem in terms of the engines power to push through, but the ergonomics of the bikes lack of weight (compared to a road bike) are what will become your true adversary.

[@amelica5502]

@@TeamProCycle thank you so much for such a detailed and thorough response. On your 790, did you keep the stock gearing? When I look at the dyno charts even for the stock motor, it seems they have plenty enough torque at a lower RPM to gear the bike hire for the highway at least one tooth up in the front maybe three down in the back to make Highway cruising more comfortable at 75 or 80 mph. Since I'm in the desert Southwest with lots of Open Spaces distance to cover, I'm not so concerned with having a super low first gear to crawl through tight technical stuff What do you think about the gearing with the 790 kit? Would it benefit from higher gearing for the highway or should it be left alone?

[@TeamProCycle]

@@amelica5502 I have the stock gearing on the bike right now and it suites me well for the riding I do around here. If you go with the 790 kit and plan on riding at freeway speeds often, I would consider at least going up a tooth on the front sprocket. This will save on fuel consumption and engine wear over time. Same strategy applies for desert ridding. The new added power from the 790 kit will make up for the taller gearing, and I would also make sure to add a set of HD clutch springs.

[@Dastardly_X]

🤘🏻 🌟 🤘

[@TeamProCycle]

You rock!

[@АлександрКозлов-з6д]

No rust??? How?)

[@TeamProCycle]

Magic Haha

[@sebreenWA]

Way too quick. A bit more detail in what and why. Jumped everywhere.

[@TeamProCycle]

Thank you for the great feedback. We will make sure we work on that moving forward.

[@just_one_opinion]

with all that time and money spent on that bike, why not just buy a good bike?

[@TeamProCycle]

What is a good bike to you? A good bike to one person may be something more road worthy, another may want a hard enduro bike. Considering this bike was picked up for $2k, and the parts added another $4k. What bike can you get that has the same reliability / capability / power and is customized to the owners liking / preferences right off the bat for $6k?

[@bradsanders6954]

Ive had many KTM's. A DR and most any KTM dual purpose bike arent in the same realm, not even vaguely close. I paid 3K for my 03 DR650. Ive kept the mods down to the 3K level, no bling, just stuff that works. Ive sold some bling/junk that came highly recommended but was non functional junk. You can make the bike worse with some of this shiny useless stuff, that looks cool. Gotta remember there is money to be made by selling endless tacky/crap stuff for these bikes. And yes, for the price of a fully modded DR, a very nice KTM can be had that will just roost all over any DR made. A bone stock KTM.