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Old 11-21-2012, 12:56 AM   #71341
Jammin
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Joined: Jan 2006
Location: New Delhi - new 'home' for post RTW
Oddometer: 1,535
Thanks for all your input, guys. You all rock!

@Randomroad: thanks for those tips. I used to work for a cellphone manufacturer in Chicago and initially was part of the backend (mechanical) engineering team, root-causing failures on the proto-type line, so I understand what you did and I'm applying a lot of what I learned on that job here: going through a process of elimination, but as best as I can in the 'field'

@Adv Grifter: the new stator that I installed from Procycle came with a new pickup coil and wires leading to the CDI. The problem persists even after I disconnected the stator, so I don't think it's the pickup coil. Problem persists even after I disconnected the regulator, so that's not it, either. Yeah, bummer about using second-hand donated parts, but that's what I've got here.
I did not mod my ignition switch. I'm aware of that hidden resistor and haven't touched it. All the switches on my dash (and other farkles: horn, gps, 12v socket) sit on top of the bike's harness, they plug in via a relay directly to the battery, so I dont think a short in there somewhere would cause a power loss, right?

@C/W: yup, sounds like a short to me. Going to try and replace the wiring harness when I get a chance. It's pouring down tropical thunderstorm here and no good covering to work on the bike.

@BergDonk: I checked the ignition coil connector, looks good to me. I installed my spare coil yesterday and bike was running for a bit. When this problem first surfaced, my first thought was a fuel starvation issue. I opened up the carb and saw that the float needle wasn't that smooth in its jet, so I lightly sanded the jet, got better motion for the float needle, but problem persists. What else in the carb should I look at? I have a Mikuni TM38 flat slide. I had it rebuilt before I left Nairobi and replaced the slide, float pin, air screw and reseated the float needle.

@DRT: good tip to check the fuel filter, will do.

@Multisurface Rider: good tip on cracked plug wires. I have a spare set of ignition coils with plug wires and plug caps. Problem persists with either set.

@Feelers: thanks for the that comprehensive breakdown
CDI: I have 3 on hand: original 98, take-off from a 2001 in South Africa and a good 2006 one from Arizona (installed)
Regulator: I have 2: original 98, take-off from the 2001 (installed)
Ignition coil with plug wires and caps: I have 2 sets: original 98 and 2001 (installed)
Stator: I have 2: original 98 and new 250W from Procycle with new pickup coil (installed)

I don't notice other electrical problems when it dies. I turned off the headlight, to reduce straining the battery.

I didn't bypass the neutral safety switch but did bypass the sidestand and clutch safety switches. Will check them when the rain subsides. I'll also check the handlebar kill switch.

I did replace the pickup coil as it came with the replacement stator, but I don't know if it's failed since I installed it 250 miles ago.

@heirhead: yeah, maybe the new pickup coil has failed already.
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Old 11-21-2012, 01:05 AM   #71342
BergDonk
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Location: Snowy Mountains Oz
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Quote:
Originally Posted by Jammin View Post
...........
@BergDonk: I checked the ignition coil connector, looks good to me. I installed my spare coil yesterday and bike was running for a bit. When this problem first surfaced, my first thought was a fuel starvation issue. I opened up the carb and saw that the float needle wasn't that smooth in its jet, so I lightly sanded the jet, got better motion for the float needle, but problem persists. What else in the carb should I look at? I have a Mikuni TM38 flat slide. I had it rebuilt before I left Nairobi and replaced the slide, float pin, air screw and reseated the float needle.

..............
I'm not familiar with the TM38. What sort of filtration setup do you have? The fuel taps will likely have filters in them inside the tank. I remove them and just have a single in line servicable filter on the way to the carb. Do you still have the stock inline filter that sits in the intake pipe on the BST? I aslo routinely run on reserve so any accumulation of crud in the bottom of the tank gets flushed into the filter.

Does the float bowel have a drain valve/screw? If so, if you can get a piece of clear tube and attach it to the drain and leave the valve open and route the tube up so you can get a visible float level. Then when it stops, check the level in the tube. A manometer arrangement and it should be enough to tell you if itsa fuel issue.
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Old 11-21-2012, 02:08 AM   #71343
Nullarbor63
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Joined: Mar 2009
Location: Western Australia
Oddometer: 23
My friend, I come back to the forum after a break, to read your post with fresh eyes, and my first impression is that you seem to be hung up on the concept of an electrical fault (understandably). Might I offer a different idea? I have a fair bit of history with four valve 250 and 500cc Honda singles and they had a common fault in that the cylinder head would crack between the spark plug hole and the exhaust valve seat. When they were cool this would not affect the starting of the bike, but as it heated up (especially under load and heat) the crack would expand, the cylinder head would lose compression and the bike would stop. The only foolproof way of checking for this condition is to remove the head, decoke and polish the combustion chamber and look for the crack. On clean aluminium the crack would be quite obvious. I don't know if DRs are susceptible to this, but it's a thought, and seems to fit your symptoms. I've just finished Ted Simon's 'Jupiters Travels'. Good luck with your trip.
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Old 11-21-2012, 04:24 AM   #71344
greer
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Joined: Jul 2005
Location: Glasgow, Kentucky
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Jammin's Troubles

Please bear in mind I know diddleysquat about anything mechanical. But is there any way that new-fangled battery could be causing something funky in the electrical system? Seems like I read some such about that early on in the development of these batteries.

Sarah
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Old 11-21-2012, 05:08 AM   #71345
Hasanito
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Joined: Jun 2012
Location: Kalgoorlie, Perth
Oddometer: 39
Has anyone upgraded from DR650 into 790cc

Just curious, how many people did the full procycle upgrade on their DRs to 790cc.
I couldn't find much info on this thru search...

How much difference was there and in terms of weight/power ratio, any drawbacks?
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Old 11-21-2012, 06:18 AM   #71346
nsrrider
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Joined: Dec 2010
Location: sunny Central Oregon
Oddometer: 25
Quote:
Originally Posted by Jammin View Post
Thanks for all your input, guys. You all rock!

@Randomroad: thanks for those tips. I used to work for a cellphone manufacturer in Chicago and initially was part of the backend (mechanical) engineering team, root-causing failures on the proto-type line, so I understand what you did and I'm applying a lot of what I learned on that job here: going through a process of elimination, but as best as I can in the 'field'

@Adv Grifter: the new stator that I installed from Procycle came with a new pickup coil and wires leading to the CDI. The problem persists even after I disconnected the stator, so I don't think it's the pickup coil. Problem persists even after I disconnected the regulator, so that's not it, either. Yeah, bummer about using second-hand donated parts, but that's what I've got here.
I did not mod my ignition switch. I'm aware of that hidden resistor and haven't touched it. All the switches on my dash (and other farkles: horn, gps, 12v socket) sit on top of the bike's harness, they plug in via a relay directly to the battery, so I dont think a short in there somewhere would cause a power loss, right?

@C/W: yup, sounds like a short to me. Going to try and replace the wiring harness when I get a chance. It's pouring down tropical thunderstorm here and no good covering to work on the bike.

@BergDonk: I checked the ignition coil connector, looks good to me. I installed my spare coil yesterday and bike was running for a bit. When this problem first surfaced, my first thought was a fuel starvation issue. I opened up the carb and saw that the float needle wasn't that smooth in its jet, so I lightly sanded the jet, got better motion for the float needle, but problem persists. What else in the carb should I look at? I have a Mikuni TM38 flat slide. I had it rebuilt before I left Nairobi and replaced the slide, float pin, air screw and reseated the float needle.

@DRT: good tip to check the fuel filter, will do.

@Multisurface Rider: good tip on cracked plug wires. I have a spare set of ignition coils with plug wires and plug caps. Problem persists with either set.

@Feelers: thanks for the that comprehensive breakdown
CDI: I have 3 on hand: original 98, take-off from a 2001 in South Africa and a good 2006 one from Arizona (installed)
Regulator: I have 2: original 98, take-off from the 2001 (installed)
Ignition coil with plug wires and caps: I have 2 sets: original 98 and 2001 (installed)
Stator: I have 2: original 98 and new 250W from Procycle with new pickup coil (installed)

I don't notice other electrical problems when it dies. I turned off the headlight, to reduce straining the battery.

I didn't bypass the neutral safety switch but did bypass the sidestand and clutch safety switches. Will check them when the rain subsides. I'll also check the handlebar kill switch.

I did replace the pickup coil as it came with the replacement stator, but I don't know if it's failed since I installed it 250 miles ago.

@heirhead: yeah, maybe the new pickup coil has failed already.
I think you can rule out the resistor buried in the ignition switch.......if it is fried the switch duznt work........
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Old 11-21-2012, 06:40 AM   #71347
Albie
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Location: NWA
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Quote:
Originally Posted by barko1 View Post
Southwest Moto Tire is in Tucson, they used to have most everything.
Actually, they used to pretty much drop ship everything. Worked great for me because living in Dallas back then it was next day shipping from Parts Unlimited. I stopped buying from them back when they got bought out and jacked up their prices.
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Old 11-21-2012, 07:42 AM   #71348
Rusty Rocket
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Joined: Dec 2005
Location: Trying to leave CT
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Quote:
Originally Posted by Albie View Post
Actually, they used to pretty much drop ship everything. Worked great for me because living in Dallas back then it was next day shipping from Parts Unlimited. I stopped buying from them back when they got bought out and jacked up their prices.

Do mean you stopped buying from SWMotoTire, or PartsUNL?



I just shopped tires (5 mins ago after seeing the name) at SWMT and their prices seemed pretty good. Anywhere better? I love saving munney.
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Old 11-21-2012, 07:55 AM   #71349
Rob.G
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Joined: Jan 2010
Location: Fulltiming in an RV!
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Quote:
Originally Posted by Hasanito View Post
Just curious, how many people did the full procycle upgrade on their DRs to 790cc.
I couldn't find much info on this thru search...

How much difference was there and in terms of weight/power ratio, any drawbacks?
There are some people here with the 780 and 790 kits... the posts I've seen indicate that it's a very worthwhile mod. I plan to do it hopefully before the end of next year. But my little KLX250S needs the 351 kit first. The DR already has pretty respectable power stock. The KLX? Not so much. :)

Rob
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Old 11-21-2012, 08:05 AM   #71350
dljocky
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Joined: Dec 2008
Location: Yorktown, Va
Oddometer: 853
I've got a 2009 that I bought new 2.5 yrs ago, and it's got 39K miles on it with no problems so far. Good luck.





Quote:
Originally Posted by Steve in Santa Fe View Post
Greetings all,

I am looking at a 2005 DR 650 that has 24,000 miles. (Mostly highway as a commuter).
The guy has full records and the bike looks well cared for.

Question: IS 24K high mileage for a DR 650 engine that has been maintained?
(I have an old BMW Boxer, where 24K is barely broken in, so my thinking may be off.

Thanks,
Steve
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Old 11-21-2012, 08:30 AM   #71351
procycle
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Location: Center of the DR650 universe
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Death Valley ride report

Still in progress. 3 more days ahead of us.
--> http://drriders.com/topic6350.html
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Old 11-21-2012, 08:45 AM   #71352
O'B
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Location: Passing By The Highway
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Quote:
Originally Posted by greer View Post
Jammin's Troubles

Please bear in mind I know diddleysquat about anything mechanical. But is there any way that new-fangled battery could be causing something funky in the electrical system? Seems like I read some such about that early on in the development of these batteries.

Sarah
I agree you should not proceed without getting another good battery to test with. Be sure to check all the associated ground points. A little patience I am sure you are almost there. It will certaianly be a WTF moment when you identify the problem.
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Old 11-21-2012, 10:10 AM   #71353
Jammin
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Location: New Delhi - new 'home' for post RTW
Oddometer: 1,535
@BergDonk: As far as I know, the TM38 does not have a built-in fuel filter. I have the Aqualine tank with two petcocks and there are screens on the inside of them. I then have an inline fuel filter (paper core) where the two fuel lines meet and before it goes into the carb inlet. Good idea on viewing the float level. Will try that when I get back to civilization.

Here's an exploded view of my carb: http://www.sudco.com/Diagrams123/exptm.gif
Anything you see in there that I can fiddle with?

@Nullarbor63: thank you, my friend. You are right that I am getting hung up on it being an electrical issue but I'm open to it being related to something else. It's just that I can't diagnose that here but once I'm back to a city, I'll do a full tear down and investigate. Thanks for bringing up the cylinder head crack issue. Didn't know about that.

@greer: you have a valid point and yes, it could be the Shorai lithium-iron battery. I'll test with a regular one once I'm back to Nairobi.

@nsrrider: yeah, I dont think it's the resistor. thanks.

@Randomroad: I can't wait for that WTF moment!

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sanDRina in the middle of a field repair in southwestern Tanzania, just before a thunderstorm rolled through:



In trying times like this, I tell myself to look for the positives and put things in perspective. I'm healthy, dry and online :)
__________________
J A Y on a 98 Suzuki DR650SE (sanDRina)

Trip Website: JamminGlobal.com
Current Ride Report: Global South | Past Trips: CDR '09, Alaska '08, Mexico '07 | YouTube Videos
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Old 11-21-2012, 10:47 AM   #71354
DockingPilot
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Location: Andover, N.J.
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Quote:
Originally Posted by FlowBee View Post
OK, thanks. S0..... we should expect a 18" conversion. $$$
Well no Flow, we should expect one to call ahead after the long ride to Texas to make sure one had a tire waiting. Like I did in Battle Mountain Nevada while riding the TAT. It was pretty easy, I called a bike shop out there before we left NJ and had him order us tires. He did, they were there.
We continued on..........

Pretty easy

Loose the edge there friend.
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Old 11-21-2012, 12:37 PM   #71355
MADurstewitz
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Joined: Jan 2009
Location: Joisey, not far from NYC
Oddometer: 159
Quote:
Originally Posted by Hasanito View Post
Just curious, how many people did the full procycle upgrade on their DRs to 790cc.
I couldn't find much info on this thru search...

How much difference was there and in terms of weight/power ratio, any drawbacks?
I did it. The mother moves. Tons of smooth power. I recommend it.
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