DR650 FAQ - Controls

Should I drill holes for switch housings in my new bars?

I am installing a new Pro-Taper Contour oversize bar on my DR650 and noticed that there is a hole drilled in each side of the stock handlebars to keep the clutch and brake side switch housings from rotating. My question is should I drill holes for those in my new bars or remove the alignment pins in the housings?

Part two of my question is that I have to replace the stock handlebar clamps with the larger units that came with the oversize bars and they are slightly offset to one side, which way should I install them?

Last but not least, the bolts that come with the oversize bars are larger than the stock bolts and do not fit through the sleeves for the rubber mounts that then attach to the triple clamp, what should I do?

Question 1 answer: Yes, you should drill holes in your new bars to keep the switch housings from spinning on the bar. If you decide that you don’t want to drill holes, you can shave off the little plastic pins, but do not cut them all the way off as you need to leave a little tab to keep the units tight on the bar.

Question 2 answer: The offset is built into the mounts to allow you to install them whichever way you prefer. Expert riders tend to mount the bars forward for additional cockpit room and to put more weight over the front wheel. Beginning riders tend to mount the bars rearward to be more comfortable when sitting.

Question 3 answer: Just use the stock bolts, they should be fine.

How do I get extra slack in the throttle cables?

I have recently installed new handlebars and it has taken all of the slack out of the throttle cables. Is there a simple way to get an extra inch of slack back into the cable to be safe or do I need longer cables?

Check the routing of the cables. Lots of users have taller bars with risers (me included) and find that the stock cables work just fine. If you can’t solve the issue with re-routing you may be able to reposition the throttle housing so that the cable runs below the handlebar rather than above it.

Where is the best place to install the grip heater switch?

I have about to install a set of grip heaters on my DR650 but cannot decide where to mount the switch, do you have any suggestions?

I installed the switch in the right side gusset of the headlight plastic. It is protected, out of the way and easy to reach. Also, before putting down the left side heating element, put a layer of tape down to insulate it from the handlebar.

Do Sunline V1 levers fit stock DR650 perches?

I want to upgrade to Sunline V1 levers and see that they only offer them for the RMZ. Do you know if those will fit the DR650 perches?

As far as I have been able to determine there are no levers from other models that are a direct swap for the DR650. Sorry, but it looks like you will have to purchase new perches as well as the levers, that should do the job. Just understnd that if you decide to go this way, you will have to do some wiring work to cover for the clutch safety switch as well as install a dual-sport type brake switch on the front brake line and wire that accordingly. We do carry a brake switches for both Japanese and European type master cylinders if you need one. If you go this route and install shorty type levers, you won't need spacers to install handguards!

Two vs. One cables for the throttle housing on 1999 DR350?

So I went to eBay and did a search for 1999 DR350 throttle tube. All of them are listed for mid 1990's to 1998, but not one seller lists one for a 1999. Keintech shows one on their website, but doesn't mention a year. So I emailed one of the eBay sellers and asked him what the deal is with the 1999 model? Then he tells me 1999 models are different, and he doesn’t have them.

The throttle tube for the 1999 model is the same as most of the earlier models. The 1990 and 1991 dual-sport models only had a single cable. I believe all other years 1992-1999 are the same with a dual-cable setup.

Do stock DR650 bars bend easily?

Will the stock DR650 bars bend easily if the bike is dropped?

With the weight of the DR behind a fall, the stock bars will bend quite easily unfortunately.

Will the stock cables work on a DR650 with the Powermadd handlebar risers installed?

If I order the Powermadd handlebar risers, are the stock cables long enough to still work with that?

Yes, the stock cables will work though you may have to reposition the throttle housing so the cables exit below the handlebar instead of on top.