I think i've seen a post saying that a 95mm DR650 piston can be used for big bore conversion. Is that right?

Hello Lancer.  I can't PM because I have posted less than 10 times. I have been leaning towards a 95 or 96mm Wossner. Your proposal is interesting but I amagine getting it sent to me here in Mallorca, Spain and through customs will be a handful. Can you quote for shipping to non-mainland Spain.

One thing though, you mention 90-95 bikes. Im picking up an '86 for a project on Saturday. I also own a '98. Did cylinder dimensions change through the lifespan of the LS?

The 94mm Wiseco is definitely the easiest and cheapest way to increase power with a piston swap.  When you need a cylinder to be bored for a larger piston - you always run the risk of the machinist getting it wrong.  Too many bike shops have a boring bar but don't really have experienced folks running it.  It is very easy to get the cylinder bore too big and you get a noisy oil burner......or they get it too tight and the pistons seizes in the bore.

The 95mm, 96mm and 97mm DR650 pistons will work in the Savage engine - but they really aren't made for it and the quench area is large and results in less than ideal performance.  The 94MM that Lancer has made is a better design and provides better performance than a larger piston designed for the DR650.  (You will need to run premium fuel).

The Lectron carbs function basically the same as  Edlebrocks Quicksilver carbs, and both are priced in the $400+ range for the carbs and $7-800 for kits for specific bikes.  Lectron sells one for the Suzuki DR650, which is as close as you will get to the Suzuki LS650 Savage/S40.  The DR kit comes with a throttle cable made for the DR, but I’m unsure if the cable-to-throttle housing attachment is the same for the DR and LS.  You will need to confirm this, and perhaps need to get another cable if they are not the same.  Their kit does not mention a new rubber mounting flange so I’m assuming it’s the same size as stock which for the DR is the same as the LS.
Besides the Wiseco piston ($229) I also have carb kits using the Mikuni VM36mm carb, with a custom throttle cable made for the LS, along with a new mounting flange for proper fit, Jet Pak with extra main & pilot jets, Mikuni carb manual,  & Uni air filter.  Kit price is $429.   In addition I have low-midrange camshafts by Webcam Inc. for $329 with your old cam core in exchange.  Without a cam core exchange the price is $429.  This cam will absolutely wake up a sleepy LS650, and even more so when combined with the piston and carb.
Shipping cost for internationally is expensive, about $80+ for Europe, but if you purchase all 3 from me (piston, carb, cam) then I pay all shipping/insurance costs.
So for just over $1,000 you can get cam-carb-piston compared to $800 for the Lectron carb alone.

Your choice, but either way I’m happy to help in any way can.

I would not use the clearance recommendations provided by Wiseco.  The Wiseco pistons were designed for an engine that utilizes an oil cooler.  The LS doesn't use an oil cooler.  I installed a number of these pistons with .0030" to .0035" clearance and never had a problem related to clearance.

Wiseco recommends .0019" clearance for their 97mm pop-top.  That always impressed me as being too tight.  Being a curious fellow, I decided to try one set up closer to the recommended clearance.  So, on my latest project, I spent a great deal of time and effort setting up the clearance right at .0022", just .0003" more that Wiseco suggests.  I should have trusted my instincts.  After a generous 2000 mile break in, I took the thing up a long 6% grade barging into a stout headwind.  The picture tells the story.

The Wiseco pistons work great and are reliable, but they need a little room to do their job.  Set em up right and they're good-to-go.

Just holler when you are ready.