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General Category >> Rubber Side Down! >> 790 Big Bore
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Message started by GIXXER on 08/02/21 at 15:18:10

Title: 790 Big Bore
Post by GIXXER on 08/02/21 at 15:18:10

Has anyone seen the 790 big bore kit for the DR650? Will it work on our LS650?

Title: Re: 790 Big Bore
Post by Fast 650 on 08/02/21 at 23:38:10

It sounds like it would be fun, but the DR cylinder will not bolt up to the LS cases. And I doubt that you could bore the LS cylinder to fit a sleeve and piston that much oversize without getting into the cylinder studs.

Title: Re: 790 Big Bore
Post by Dave on 08/03/21 at 03:46:04

The DR650 has a larger bore and shorter stroke than the LS650....so it started out with a larger bore even when stock.

The largest bore that we can get away with on the Savage is 97mm....any bigger than that and the thickness of the cylinder liner is too narrow (and I believe the counterbalancer clearance becomes an issue).

A bore of 97mm combined with the 94mm stroke results in an engine capacity of 694cc.

Title: Re: 790 Big Bore
Post by GIXXER on 08/03/21 at 04:54:40

Glad I asked the question here. I am not familiar with the DR engine's as you. Thanks for the info!

Title: Re: 790 Big Bore
Post by LANCER on 08/05/21 at 09:10:19

Suzuki made the DR800 for the European market some years ago.
Good luck finding one.

Title: Re: 790 Big Bore
Post by Gary_in_NJ on 08/05/21 at 09:26:20

Lancer, was the DR800 a thumper? I don't think I've heard of a thumper that large. It must have a 5" piston.

Title: Re: 790 Big Bore
Post by Dave on 08/06/21 at 04:59:42

The DR800 "BIG" is/was a thumper.

Not very many came to the US......more were sold in the EU.

https://www.motorcyclespecs.co.za/model/suzu/suzuki_dr800s%2091.htm

Title: Re: 790 Big Bore
Post by Gary_in_NJ on 08/06/21 at 06:32:39

105mm x 90mm bore & stroke. Two carbs. Glorious.

Title: Re: 790 Big Bore
Post by Ruttly on 08/06/21 at 11:40:34

A Big 800 engine in a Tempter Chassis , just for fun

Title: Re: 790 Big Bore
Post by Ruttly on 08/06/21 at 11:58:21

I had investigated this when I built my engine. A guy in EU was doing a 818cc but much case,crank,cyl machining to accommodate the new sleeve/cylinder. Way to much $$$$ ! Better off with a 95,96 or 97 mm big bore , way more cost effective.

My 2 cents

Title: Re: 790 Big Bore
Post by Old Savage Eddie on 08/07/21 at 06:36:33

This post got me thinking [ch129300] so I looked into DR800 big in Europe. I could not find a spare engine at a fair price, and the cheapest bike was about $2300 plus shipping- no doubt this is way to expensive for me to even consider as a project engine swap.

What was new to me is discovering that Suzuki sold the biggest displacement thumper of any manufacture:

There was a DR750 big - 727cc and 52hp@6600rpm in 1988/89

The success led to a DR800 big - 779cc and 54hp@6600rpm in 1990/96

A very cool bike…