SuzukiSavage.com - 2002 LS650 Rebuild

Iceman4193

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2002 LS650 Rebuild
05/03/19 at 11:32:52

Hey guys, been away from here for quite a while but I have my LS650 in pieces waiting to be rebuilt and I am trying to decide what mods I am gonna do. I have some of the old forum posts on Lancers build and some odds and ends stuff but what are the essentials for the rebuild and what are some good band for the buck performance mods I should do while the thing is apart?

I already have the tensioner mod done from forever ago but I am looking to change up the gearing ratio and add a bit of power to run the new taller gearing. Ideally id like to be able to cruise at 75 or so at a lower RPM and I know there are some ways of doing that but if anyone has the links to some good rebuild posts here and some pointers I'd appreciate it. Anything related to doing the overbore for the Wiseco piston, valve work, intake mods and carb swaps, sealing up the engine better so I can avoid future leaks, cam related mods, frame and handling related mods, ect...

I am not looking to spend thousands or race the thing, but I want to make it a bit more practical for highway riding and give it a little extra get up and go.

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Eegore Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 8017	Re: 2002 LS650 Rebuild Reply #1 - 05/03/19 at 12:37:09 This is an opinion of order, but it does layout some options. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1291516932 Have you browsed the Technical section of the forum?
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justin_o_guy2

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Re: 2002 LS650 Rebuild
Reply #2 - 05/03/19 at 16:13:25

You may be talented and young and strong
But you can't put the lid back on that can o worms.

You're gonna need to
Clean up the exhaust port
Install the newest cam
Open up the intake
Put on the muffler that works with everything else.
Possibly more, to get air in to balance
Might need to ditch the rubber airflow control that goes in the air box intake.
Oldfeller designed an air filter that protects the engine AND allows excellent airflow.

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Iceman4193

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Re: 2002 LS650 Rebuild
Reply #3 - 05/04/19 at 10:45:04

justin_o_guy2 wrote on 05/03/19 at 16:13:25:

You may be talented and young and strong
But you can't put the lid back on that can o worms.

You're gonna need to
Clean up the exhaust port
Install the newest cam
Open up the intake
Put on the muffler that works with everything else.
Possibly more, to get air in to balance
Might need to ditch the rubber airflow control that goes in the air box intake.
Oldfeller designed an air filter that protects the engine AND allows excellent airflow.

I have a dyna muffler on there right now. I rejetted the stock carb but will probably grab a Mikuni VM or something. Do you know where that airbox mod is?

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Iceman4193

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Re: 2002 LS650 Rebuild
Reply #4 - 05/04/19 at 11:02:48

https://www.ebay.com/itm/Wiseco-Suzuki-DR650-DR-650-Piston-Kit-95mm-std-Bore-...

https://www.ebay.com/itm/Wiseco-Piston-96-00-4597M09600-For-Suzuki-Savage-650...

Are these the right pistons to be looking at?

Worth going for the 95 or 96? Im sure there is not much of a difference.

I am currently opening up the intake and exhaust a bit. Anyone have a link to a post about porting the exhaust?

What are yall using for cams right now?

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DragBikeMike

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Re: 2002 LS650 Rebuild
Reply #5 - 05/05/19 at 04:59:25

Regarding questions about porting, I did testing on improved ports. You can get the results along with detailed maps of the ports in my post titled "Cylinder head porting and flow test", currently on page 4 of Rubber Side Down.

Regarding camshafts, you can get cam timing data in my post titled "Camshaft Comparison", currently on page 9 of Rubber Side Down. I can confirm that the 1995 & earlier DR650 cam works good and its cheap. You can get the details on the DR650 cam in my post "DR650 Cam Evaluation", currently on page 2 of Rubber Side Down.

Regarding air filters and airbox mods, you can get detailed info in my post titled "Airfilter Flow Tests", currently on page 9 of Rubber Side Down, and my post titled "Airbox Performance Tests", currently on page 10 of Rubber Side Down.

Sorry about not providing links. I just can't seem to master that tidbit of IT wizardry. Feel free to PM if you have specific questions.

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Knowledge is power.

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Iceman4193 Junior Member Offline SuzukiSavage.com Rocks! Posts: 96	Re: 2002 LS650 Rebuild Reply #6 - 05/05/19 at 17:50:40 Thanks Mike, I will take a look!
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Iceman4193 Junior Member Offline SuzukiSavage.com Rocks! Posts: 96	Re: 2002 LS650 Rebuild Reply #7 - 05/25/19 at 19:19:52 Where are you all getting your gaskets from? Good brands to go with?
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Iceman4193 Junior Member Offline SuzukiSavage.com Rocks! Posts: 96	Re: 2002 LS650 Rebuild Reply #8 - 06/08/19 at 10:01:47 If I go with a 94mm Wiseco, and a DR650 cam, how do I handle the jetting on my carb? I know a while back I did the mixture screw change and got the jet kit from someone on here but I am assuming I will need to rejet after these changes?
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Dave

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Re: 2002 LS650 Rebuild
Reply #9 - 06/08/19 at 12:29:50

Iceman4193 wrote on 06/08/19 at 10:01:47:

If I go with a 94mm Wiseco, and a DR650 cam, how do I handle the jetting on my carb? I know a while back I did the mixture screw change and got the jet kit from someone on here but I am assuming I will need to rejet after these changes?

You may not need to rejet......you will only know after you get it running.

Get a few jets just in case - you should have a #150, 152.5 and 155 main, #50, 52.5 & 55 pilot jet.....however I would doubt you need the #155 or #55...unless you have done some weird stuff with your air box and/or exhaust system.

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BrokeAss Junior Member Offline SuzukiSavage.com Rocks! Posts: 69	Re: 2002 LS650 Rebuild Reply #10 - 06/09/19 at 16:21:11 Stretch the swingarm 3" and achieve your gearing change during the chain conversion. Bike rides so much nicer, suspension is more compliant, and the proportions are much nicer looking.
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