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FACTORY CHANGES
2000-2001 (Standard only - no Baja edition
for 2000 or 2001)
1) Baffle added in the carburetor ($17 from
dealer)
2) Toe Settings changed
3) Early 2000 oil air vent line
4) Different magnetic clip on the bottom of the oil tank
5) Steering stem washer
6) Hose clamp on crankcase vent line at air box
7) Clamp at oil tank for vent line
8) Emissions label under seat
9) Right and left foot protectors
10) Front bumper protector plate
11) Engine skid plate
12) Rear sub frame
13) Left and right tab locks around ball joint area
14) Metal chain guard at countershaft/case saver
15) Oil tank
16) Oil vent line hose adapter
17) Adapter where oil line enters engine
18) Oil vent hose between oil tank and crankcase
19) Left and right air box snorkels
20) Plastic coolant tank
21) Wiring harness assembly
22) Longer oil filter
23) Longer oil filter cover
24) Oil pressure switch
25) Rubber sleeve for shift lever now available
26) Coolant hose clamps on hose between pump and cylinder
27) #45 starter jet (up from #32.5 on the 2000 model)
28) Stiffer carburetor spring (The carburetor assembly is different due to
internal parts)
29) Rear shock absorber bolt has lower torque spec (63ft-lbs). Some owners have
had squeaking problems
30) Updated assembly and test procedures - rear axle lock nut, ball joints
2001-2002 Standard edition
1) Radiator
2) Rubber mounted Cooling Fan
3) Front Rims
4) Rear Axle
5) Axle housing with O-ring
6) Rear Wheel Hubs
7) Rear Rims
8) Chain
9) Front Brake Hoses
10) Rear Brake Hose
11) Upper A-Arms
12) Lower A-arms
13) Front Shocks
14) Rear Seat Latch Cover & Latch Lever
15) Emission Label
16) Tool Kit
17) The plug wires on new coils are a tiny bit longer, making it easier to keep
the wires away from ground.
18) Different battery
2002 Standard vs. Baja edition
1) Orange & Black color
2) Wheel offset (1/4" narrower per side)
3) Ohtsu Radial tires Front & Rear
4) 2 Additional headlights
5) Autometer 10k RPM Tachometer
6) Rev limit increased to 7900 RPM up from 7700
7) Re-enforcing rings added to the outside of rims
8) DS650 logo aluminum guard on silencer
9) Chain Roller
10) New front bumper with a ‘Cheshire Cat’ style grin
11) Black & Orange Shock covers
12) Foot peg extension
13) Hand guards
14) New grips
2002 vs. 2003
1)
Re-enforced air duct between air box and carburetor to prevent collapsing
2) Slight change in graphics on rear fender of
Baja edition
3) Viper Red model added (non Baja model DS650)
4) Ohtsu Tires standard on all DS650s
5) Rolled edge rims on non-Baja models
6)
Black and Yellow DS650 models discontinued
2003 vs. 2004
1) Aluminum upper A-Arms (only on early 2004
models, later models are steel)
2) Swing arm shortened by 0.5”
3) Chain adjustment procedure & related
hardware is changed
4) More Horsepower (unconfirmed)
5) Narrowed width (about 1” narrower)
6) Steel Braided brake lines (Baja X model only)
7) New Headlight assembly – (weighs 3lbs instead
of 6) and uses two H6 or H6M bulbs)
8) Plastic trim around headlight (to ease the fit
of the new headlight assembly)
9) Lighter Swing Arm
10) Lighter Axle Nut
11) Lighter Sprocket Hub
12) Lighter Wheel Hubs
13) Baja X model added – Includes various skid plates, HPG
(High Pressure Gas) Shocks, Nerf Bars, etc.
2004 vs. 2005
1) All 2005 models use Steel upper A-Arms
2) Baja model discontinued (only Baja X and standard DS now)
3) Baja X model is now Black / Orange instead of Black / Yellow
4) Viper Red DS650 has new graphics, and new plastics with even more red
Do you know of a factory change that we missed
here? If so, e-mail us at admin1@ds650.net.
Thanks!
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