I found a useful thread on VRSI which outlines which parts are swap-able between the various models over the years; I'm pretty sure there are minimal differences between US and UK spec bikes.
The intention of this FAQ is to see which part could work if your bike fails or an accident occurs in the middle of nowhere. But can also be used to determine if a part can be swapped in general.
Legend:
1. Works on all models. Means part can be used on all DL1000’s (also KLV1000) & DL650’s.
2. All 1000’s can be swapped & all 650’s can be swapped. Means swap only between 1000’s & only between 650’s & not between 1000 & 650.
3. Early 1000. Means K2 (2002) & K3 (2003) DL1000’s.
4. Late 1000. Means K4 (2004) – L0 (2010) DL1000’s.
5. Early 650. Means K4 (2004) – K6 (2006) DL650’s.
6. Late 650. Means K7 (2007) – L0 (2010) DL650’s.
Handlebar & Controls:
Handlebars – Works on all models. Some minor variations over the years, but will work.
Bar ends – Early 1000 & all 650 not using handguards can be swapped. Late 1000 & late 650 using handguards can be swapped.
Brake lever, front – Works on all models.
Brake pedal, rear - All 1000’s can be swapped & all 650’s can be swapped.
Clutch lever – All 1000’s can be swapped & all 650’s can be swapped.
Gear shift lever - All 1000’s can be swapped & all 650’s can be swapped.
Hand guards – Early 1000 had open end guards & all late models used closed end that attach to bar ends. Late 1000 right guard can swap with 650.
Mirrors – Works on all models. Changed design in 2004
Electrical:
Battery - All 1000’s can be swapped & all 650’s can be swapped. 1000 battery is taller & won’t fit 650. 650 battery could be used in 1000 but has less capacity.
Fuel pump relay – Works on all models.
Starter relay – Works on all models.
Tip-over sensor – Works on all models.
Side stand switch – Works on all models.
Headlamp assembly – Works on all models. There is a difference between lefthand & righthand drive models.
Tail lamp module – Works on all models. Mounting bracket is different between 1000 & 650.
Turn signals – Works on all models. Early 1000 had different design & lower wattage bulbs, but function is same. K9 & up models have clear lens.
Speed sensor - All 1000’s can be swapped & all 650’s can be swapped.
Fuel pump assembly – Early 1000 had 4 pin connector. All late 1000 & all 650 have similar 3 pin connector. Early & late pumps can be swapped if connector wiring changed. The K7 and up wee uses a different pump assembly, but will work in other model years. So bottom line is all years & models can be swapped if connector wiring is proper (or modified).
Stator, alternator – K2 DL000 has a different stator and rotor from K3 + DL1000 and can not be swapped. All K3-L0 DL1000 are swappable. K8 + DL650 has a different stator & rotor than prior models. K8-L0 DL650 can be swapped & K4-K7 DL650 can be swapped. Same swaps apply to rotors as well.
Regulator/Rectifier – Many different models. Same swaps as stator.
Switch assembly, left handlebar – For DL1000, K2-K3 are same and swappable & K4-L0 are same and swappable. The K4-K6 650 is the same and swappable. K7+ has different design (where the buttons are) but is swappable with K4-K6 and visa versa. All K4 & up DL1000 & DL650 are swappable.
Switch assembly, right handlebar – For DL1000, K2-K4 are same and swappable & the K5-L0 are same and swappable. The K4 650 is the same as the K2-K4 DL1000 an is swappable. The K5-K6 650 is the same as K5-L0 DL1000 and is swappable. The K7+ 650 has an integrated throttle housing and is only swappable with K7-L0 650’s.
Chassis:
Brake pads – Works on all models.
Brake rotor, front – K2-L0 DL1000 & K4-K6 DL650 are the same & swappable. Some difference of center color, which can be silver, gold or black. K7-L0 DL650 are different from all others & can be swapped for K7-L0 DL650’s only. ABS & Non-ABS rotors are the same.
Brake rotor, rear – Works on all models.
Caliper, front brake – K2-L0 DL1000 & K4-K6 DL650 are the same & swappable. K7-L0 DL650 are different from all others & can be swapped for K7-L0 DL650’s only. In an emergency early 650 or 1000 calipers could be used on late 650, but both sides should be swapped.
Caliper, rear brake – Works on all models.
Center stand - All 1000’s can be swapped & all 650’s can be swapped.
Driver’s Footpegs - Works on all models.
Driver’s Footpeg Brackets – Works on all models. Springs are different between 1000 and 650.
Pillion Footpegs & brackets – Works on all models. Right side 1000 onto late 650 may need small spacer to clear fat exhaust.
Fork springs – DL1000 & DL650 springs are not swappable. K2 DL1000 springs are different from all other DL1000 and should not be swapped to other years. K3-L0 DL1000 springs are swappable. Early 650 springs are swappable between early 650’s & late 650 springs are swappable between late 650’s.
Fuel Tank Mount, rear – Works on all models.
Fuel Tank Mount, front – Works on all models.
Luggage rack. rear – Works on all models. Silver though K4 & black after.
Master cylinder, front brake – Works on all models except late 650. Late 650 has different unit.
Master cylinder, rear brake - Works on all models.
Cushion lever – Works on all models.
Cushion rod (dog bone) – Works on all models.
Shock absorber – Works on all models. 650 shock is slightly shorter & has a lighter rate spring.
Side stand - All 1000’s can be swapped & all 650’s can be swapped.
Steering stem (lower triple clamp & stem) – Works on all models. ABS 650’s have a mounting point for ABS brake hose joint.
Steering stem head (upper triple clamp) – Works on all models. DL1000 part has rubber mounted handlebar clamps.
Swingarm - All 1000’s can be swapped & all 650’s can be swapped. Silver through K4 & black after. Late 650 is longer than early 650.
Wheel rim, front - All 1000’s can be swapped. All early 650’s can be swapped. Late 650‘s can be divided into ABS & Non-ABS. Swaps between the two types are problematic & best not done. Swaps between 1000 & 650 are somewhat possible with complete front end change, that’s forks, rim, axle & spacers. 1000 onto 650 would have speed sensor problems & can not be done on ABS 650.
Wheel rim, rear - Works on all models. Late 650 ABS wheel has place for sensor ring.
Body:
mudguard, front – Works on all models.
Frame cover – Works on all models.
Fuel tank - Works on all models.
Lower cowl cover - All 1000’s can be swapped & all 650’s can be swapped.
Meter panel surround – Works on all models K4 and later. K2-K3 DL1000 is different style.
mudguard, rear - All 1000’s can be swapped & all 650’s can be swapped.
Inner mudguard, rear - All 1000’s can be swapped & all 650’s can be swapped. Late 650 is two part mudguard and can be used on early 650, but probably not the best thing to do. Early 650 part should not be used on late 650.
Saddle, OEM – Works on all models. This applies to stock 650, stock 1000, low touring, high touring & gel. May have some fitment problems between early & late DL650’s with aftermarket seats, mainly Corbin.
Side cowling, rear – All 1000’s can be swapped & all 650’s can be swapped.
Side cowling, front - All 1000’s can be swapped & all 650’s can be swapped.
Top cowl – Works on all models K4 and later. K2-K3 DL1000 is different style. For a couple years of 1000 had silver instead of the black for most years.
Windscreen - Works on all models K4 and later. K2-K3 DL1000 is different style.
Windscreen brackets - Works on all models K4 and later. K2-K3 DL1000 is different style and didn’t have brackets.
Motor:
Air filter – Works on all models. Later years have integrated gasket which is best. Part # 13780-27G10.
Oil radiator - All 1000’s can be swapped & all 650’s can be swapped.
Coolant radiator - All 1000’s can be swapped & all 650’s can be swapped.
Author: Michael (castle-of-teck)
