SuzukiSavage.com - Top end damage and rebuild

LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10801 Oklahoma Gender:	Re: Top end damage and rebuild Reply #45 - 10/28/22 at 04:31:48 I’ve ran the 97mm Wiseco piston (the DR650 version, pop top style) for years without a decomp system and have had no starting issues.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #46 - 10/28/22 at 04:51:42 Thanks for that Lancer. I ordered the 400 head. How does it run with that piston vs stock ? Noticeable power improvement?
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10801 Oklahoma Gender:	Re: Top end damage and rebuild Reply #47 - 10/28/22 at 12:13:39 Yes.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #48 - 10/28/22 at 15:30:55 Hello guys. These are the images of the 400 head. How do you think it looks?
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #49 - 10/28/22 at 15:31:21 And the cap
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: Top end damage and rebuild Reply #50 - 10/29/22 at 04:16:34 Head looks good. Don't run those rockers.....get the newer ones with the hardened pads.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #51 - 10/29/22 at 04:20:34 Thanks Dave. Do you happen to know the part number ? Will need a new cam too. Would like to upgrade from the stock one.
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TheSneeze Serious Thumper Offline Posts: 1313 Northern Nevada Gender:	Re: Top end damage and rebuild Reply #52 - 10/29/22 at 09:25:18 Get the cam from a '95 DR650. I have part numbers for both the cam and the rockers in my shop. When I am done with my coffee (and get out of my bunny slippers) I will get them and post them here. EDIT Cam p/n 12711-12D00 Rockers p/n 12840-24B10, 12850-24B10
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #53 - 10/29/22 at 18:03:04 Thanks sneeze. I'll run that cam and new rockers and may need to bore and hone the cylinder. I'll go to 96mm I think.
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TheSneeze Serious Thumper Offline Posts: 1313 Northern Nevada Gender:	Re: Top end damage and rebuild Reply #54 - 10/30/22 at 08:04:18 Depending on the piston you go with, you will need to check the valve to piston clearance to make sure you do not have any interference. You can alter the deck height by using different thickness cylinder base gaskets. There is a company in the US that will make different thickness copper gaskets to achieve this.
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DragBikeMike

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Re: Top end damage and rebuild
Reply #55 - 10/30/22 at 10:18:17

I suggest you find a parts fiche for the 400 and verify that the valves, guides, springs, retainers & cotters are the same as the 650. If any of those parts are different, you might have a valve travel problem. It would also be prudent to check the cam part number too. If the 650 has more lift than the 400 the valve components might not provide enough travel to accommodate the 650 cam.

The 650 part numbers are:

Cam 12711-24B11

Int valve 12911-24B01

Exh Valve 12912-24B01

Valve Guides 11115-44B70

Springs 12920-37402

Cotters 12932-82000

Retainers 12931-45001

Don't forget the rocker arms and rocker shafts. Cross reference those too. The exhaust rocker probably has a different part number due to the absence of the compression release. Make sure the shafts have the same part numbers or you might have a problem fitting the 650 rocker arms into the 400 head cover.

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Knowledge is power.

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Moarpower

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Posts: 331

Re: Top end damage and rebuild
Reply #56 - 10/30/22 at 16:54:23

Thanks for that advice.

From what I can find, which is tricky as the 400 was Asian markets only

Cam - LS400 is listed as 1271124B04 which does match earlier revisions of the 650

Intake valve - match

exhaust valve - match

springs - match

Valve rocker shafts - Int Exh both match

Rockers - Both match.

Thats all I could find after a quick search.

Hopefully that means I'm in the clear.

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« Last Edit: 10/30/22 at 17:58:26 by Moarpower »

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #57 - 10/30/22 at 22:34:15 I'm going to be opening the case next week. I just had shoulder surgery so need to give myself a little time to recover. As I'm rebuilding the top end and replacing the piston, what other things like bearings and seals should I replace while we are at it ?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Top end damage and rebuild Reply #58 - 10/31/22 at 10:36:13 If you had rotator cuff surgery you need more than a week, a lot more.
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Moarpower

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Re: Top end damage and rebuild
Reply #59 - 10/31/22 at 19:26:36

justin_o_guy2 wrote on 10/31/22 at 10:36:13:

If you had rotator cuff surgery you need more than a week, a lot more.

Bicep and labrum tear. SO not as severe as RC thank god.

I have decided to go for this piston from Wossner but wanted to see what you guys thought before I make the purchase. As this one is just under 97mm I may be able to get one more bore to 97mm with the Wiseco? If I keep it that long.

https://www.firestormmotorcycles.com.au/suzuki-dr650-1990-1995-wossner-piston...

Finding the DR650 cam is proving difficult as new parts are half what I paid for the bike.

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« Last Edit: 11/01/22 at 15:12:52 by Moarpower »

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