DR power increase
From the research I have done:
Stage 1: Drill the airbox 'airbox mod', re-jet the carb, grind out the header pipe weld (where it exits the engine). Pretty minimal cost, and will give you better, smoother access to the power if only marginally increasing the HP.
Stage 2: Pumper Carb modification a'la MXRob (mentioned above) and a better flowing exhaust - one or both at the same time. The '01-'02 GSXR 1000 (best) or 600/750 (still good) pipe is recommended as the top choice for performance/ weight/ noise balance. Both bolt on with an adapter mid pipe ($210).
Stage 3: Big bore and hotter cams, head work, etc. I'm sure there is 50hp in there somewhere, but personally I think pushing the DR650 this far defeats the point and takes away from what really makes this bike excel as an adventure touring option- low cost, durable, frugal, simple to fix, etc.
I just picked up a low km '08 model, have found a GSXR pipe and am planning on doing the airbox cut out and re-jetting of the stock carb. From other owners reports, that seems to yield the best bang for the buck, while still keeping the fuel economy and durability at stock levels. Great bike, I'm looking forward to setting it up for back-road touring.
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