Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Suzuki Tech

Suzuki Tech Suzuki Tech Forum - For Questions specific and of interest to Suzuki riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 2 Jan 2012
Contributing Member
Veteran HUBBer
Join Date: Jan 2006
Location: Sheffield
Posts: 1,036
I am assuming that the engine number is stamped on the main casing? If the casing is OK you could get a replacement engine and have the internals dropped into you old casing and use the replacement barrels and head.

In the UK changing numbers isn't a problem, and bizarrely neither is grinding the numbers off an engine and selling it - or putting said numberless engine into a road registered bike which sounds odd but the DVLA says is fine.
Reply With Quote
Old 2 Jan 2012
Registered Users
Veteran HUBBer
Join Date: Jul 2010
Location: Australia
Posts: 164
Cheers and plans

Thanks everyone for your input through the stages! It's been a great learning experience and definitely has an effect on the trip direction one way or another.

I've been weighing up my options and at this stage they look to be...

1. (unlikely) pay $4400 to get the engine fully rebuilt

2. Found a 2008 bike on kijiji with 6200km on the clock and may use that engine as a replacement and pick off the rest of the bike for replacement parts and spares, and possibly part it out. Means I have to pay the $400 engine split and diagnostic fee at the mechanics.

3. Buy the engine from a 2005 bike (from the shop that had a top end rebuild done and the guy didn't pay up) with 7500km on the clock. Will cost $2000 for the engine and they will waive the $400 diagnostics fee. Must ask why it was being rebuilt at 7500km next time I ring.

4. Option 2 or 3 but have the engine put inside the crankcase of my 2010 engine so I can retain the engine number, as Grant pointed out, will be vital to match up later down the track. This can be done without a mechanic I assume.

Any opinions, suggestions and ideas are welcome, no matter how professional or not!
'10 Suzuki DR650. 2011+ RTW trip. Currently Coen, Cape York Peninsula. www.followtheakubra.blogspot.com
Reply With Quote
Old 3 Jan 2012
Contributing Member
Veteran HUBBer
Join Date: Jan 2006
Location: Sheffield
Posts: 1,036
I've never worked on a DR engine but I imagine you will need a hydraulic press to get the big end bearings out and in which I'd say is a mechanic job unless you have one at home. Judicious use of a low oven and a freezer might work for getting them back in.

Checking the crank journal clearance would also probably be a good move if swapping internals over as one will have worn with the other so might not fit right when swapped.
Reply With Quote
Old 4 Jan 2012
Registered Users
Veteran HUBBer
Join Date: Apr 2007
Location: Helsinki
Posts: 1,611
Originally Posted by brianrossy View Post
4. Option 2 or 3 but have the engine put inside the crankcase of my 2010 engine so I can retain the engine number, as Grant pointed out, will be vital to match up later down the track. This can be done without a mechanic I assume.
With all the other destruction, are your engine´s crankcases still fully ok to use then?

Then it might be possible, but just beware, that there are several different versions of the DR650, and also spec-codes for different markets (EU, USA, OZ), so I´d advice to first double-check, that all parts are compatible.

And you´re still talking about a major bottom-end operation here. Personally I wouldn´t try it, unless I had pretty solid mechanical knowledge and experience, a garage with proper tools, and the workshop manual to guide me. It´s not rocket-science, but you still can´t afford to make mistakes on that.

Are you at the moment close to making the decision on what will be the best way to go...? It really sucks, what happened, but I guess you were kinda lucky, in the sense, that you were just about to have a break from riding anyway!
Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
DR650 SE or KTM Adventure? Zimi Which Bike? 31 16 Feb 2012 20:07
Luggage/load: DR-Z400 vs DR650? Chinggis Which Bike? 4 2 Nov 2011 20:46


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

Next HU Eventscalendar

See all events


Latvia to Australia, an inspirational 5 month journey full of unexpected adventures!

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 00:02.