Suzuki DR650 Suspension Page

 

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Suzuki DR650 Suspension Page

 

Suzuki DR650

 

Suspension

Now that the pre 1996 DR650 are relics, it can be difficult to find aftermarket suspension parts.  But there are still options.

 

Stock Rear DR650 Shock

Stock Rear DR650 Shock

 

The Spring pre-set length for 1994-1995 stock rear shock:

STD : 240.0mm (9.45in)
Softer : 244.0mm (9.61in)
Stiffer : 235.5mm (9.27in)

 

The Spring pre-set length for pre 1994 stock rear shock:

STD : 236.0mm (9.29in)
Adjustable : 230.0-248mm (9.06-9.76in)

 

Stock Front DR650 Shocks

Stock Front Shocks

 

The front forks were changed to a larger diameter in 1996 so new and old forks aren't interchangeable.  That said, many of the front suspensions on bikes are interchangeable, allowing you to go to larger forks if you change out the entire front end.  The larger shocks can later be replaced or upgraded to work with the weight of the rider and your DR650.

 

Öhlins Rear Shock (SU106)

Öhlins Rear Shock (SU106)

 

Öhlins Rear Shock (SU106) Set-up Data:

Total length 385 mm
Stroke 95 mm
Preload spring 18 mm
Rebound adjustment 14  
Compression adjustment ---  

 

Works Performance Rear Shock Data:

MAKE/MODEL YRS NO. OAL STK SPRING STD REZ REB
DR 650 90-95 Un 15.13 Y SRS $605 $659 $795
DR 650 96-04 Un 17.88 Y SRS      

 

Progressive Suspension Fork Springs Data:

Order No 11-1506
Free Length - In.  22.50
Free Length - MM  572
O.D. - In.  1.35
O.D. - MM.  34
Rates lbs/in  30/40
Rates kg/mm  .59/.71
Spacer  10.00

 

 

Related links:

 

Related Links Post '96 DR 650:

 

 

Front Suspension Maintenance

 

From the Suzuki 93-95 DR650 maintenance manual:

 

OUTER TUBE METAL, OIL SEAL AND DUST SEAL

 

09940-50113: Front fork oil seal installer

 

CAUTION:

Use special care to prevent damage to the teflon coated surface of the Anti-friction metal when mounting it,

 

CAUTION:

Install dust seal stopper ring securely.

 

FORK OIL

 

Fork oil type: Fork oil # 10

Fork oil capacity: 536 ml (18.1/18.9 US/Imp qt)

 

 

NOTE:

When adjusting oil level, remove the fork spring and compress the inner tube fully.

 

STD oil level: 164 mm (6.46 in)

 

09943-74111: Fork oil level gauge

 

FRONT FORK REMOUNTING

 

From the Suzuki 96- DR650 maintenance manual:

 

REMOVAL AND DISASSEMBLY

  • Remove the front wheel.
  • Remove the front brake caliper.
  • Remove the front brake hose clamp bolt.
  • Remove the speedometer cable guide bolt.
  • Slightly loosen the front fork cap bolt after loosening the front fork upper clamp bolt to facilitate later disassembly.
  • Remove the front fork by loosening the lower clamp bolts.
  • Remove the front fork cap bolt, spacer, washer and spring.
  • Invert the fork and stroke it several times to drain fork oil.
  • Hold the fork inverted for a few minutes to drain fork oil.
  • Remove the damper rod bolt with a 8 mm hexagon wrench and special tools.

    09910-31520: "T" handle

    09940-34592: Attachment "G"

  • Remove the damper rod with spring
  • Remove the boot by loosening the clamp screws.
  • Remove the dust seal stopper ring.
  • Separate the inner tube from the outer tube.
CAUTION
  • The removed dust seal and oil seal should be replaced.
  • When separating the inner tube from the outer tube, both anti-friction metals may be damaged and must be replaced with new ones.

 

 

INSPECTION

FORK SPRING

Measure the fork spring free length.  If it is shorter than service limit, replace it.

Service Limit: 548 mm (21.6 in)

 

INNER TUBE AND OUTER TUBE

inspect the inner tube sliding surface for any scuffing and check for bend.  Inspect the outer tube sliding surface for any scuffing.

 

DAMPER ROD RING

Inspect the damper rod ring for wear or damage.

 

 

REASSEMBLY AND REMOUNTING

Reassemble and remount the front fork in the reverse order of removal and disassembly, and also carry out the following steps:

 

INNER TUBE METAL

  • Install the metal by hand.

 

CAUTION
Use special care to prevent damage to the "Teflon" coated surface of the Anti-friction metal when mounting it.

 

OUTER TUBE METAL, OIL SEAL AND DUST SEAL

  • Clean the metal groove of outer tube and metal outer surface.
  • Apply grease to the lip of new oil seal.

    99000-25030: SUZUKI SUPER GREASE "A"

  • Install the outer tube metal, oil seal retainer, oil seal and dust seal.

    09940-52860: Front fork oil seal installer

 

CAUTION
Use special care to prevent damage to the "Teflon" coated surface of the Anti-friction metal when mounting it.

 

  • Install the dust seal stopper ring.

 

CAUTION
Make sure that the oil seal stopper ring fitted securely.

 

DAMPER ROD BOLT

Apply THREAD LOCK "1342" to the damper rod bolt and tighten it to the specified torque with the special tools and 8mm hexagon wrench.

 

99000-32050: THREAD LOCK "1342"

09940-34520: "T" handle

09940-34592: Attachment "G"

 

Damper rod bolt: 30 N-m (3.0 kg-m, 21.5 lb-ft)

 

 

FORK OIL

  • For the fork oil, be sure to use a front fork oil whose viscosity rating meets specifications below.

 

Fork oil type : Fork oil #10

Fork oil capacity: 565 ml (19.1/19.9 US/Imp oz)

 

  • Holding the front fork vertical and adjust the fork oil level with the special tool.

 

NOTE:

When adjusting oil level, remove the fork spring and compress the inner tube fully.

 

09943-74111: Fork oil level gauge

Oil level: 164 mm (6.5in)

 

 

FORK SPRING

  • Install the fork spring close pitch side up.

 

 

FRONT FORK REMOUNTING

  • Align the top surface of the inner tube to the top surface of the steering stem upper bracket.
  • Tighten each bolt to the specified torque

 

Front fork cap bolt: 23 N-m (2.3 kg-m, 16.5 lb-ft)

Upper clamp bolt: 29 N-m (2.9 kg-m, 21.0 lb-ft)

Lower clamp bolt: 26 N-m (2.6 kg-m, 19.9 lb-ft)

 

 

 

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