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Old 07-07-2008, 10:36 AM   #15001
itsforrest
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Base gasket fix, parts list?

Well, I gave my DR650 a good thrashing in the woods yesterday. When I stopped for a break, I found my right boot oiled along with the top and right side of the motor. It's an '02 so I knew it might do this but I hoped it wouldn't. Unfortunately, the cam chain tensioner gasket looks dry and the base gasket looks sogged in the usual place.

I'm going to do the work myself. In the interest of getting it done in one push, I want to make sure I have everything needed before I start. So, what do I need? Is everything I need on my list?

I know I need;
Head gasket,
Base gasket,
Cam chain tensioner gasket,
form-a-gasket for cam box,
assembly lube for cam bearings (does all of this have to come apart?),
exhaust gasket

From the manual, it looks pretty like a straight forward job. Is there anything to watch out for in the process that the manual doesn't note?

Thanks in advance for shared wisdom here.
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Old 07-07-2008, 10:41 AM   #15002
LukasM
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Quote:
Originally Posted by macdesign
To everyone else, has anyone hung a set of KTM640 USD's on one?
I've got a set laying about and it's always easier to learn from someone else's experiences.
Yeah, some people have done it and posted in this thread. I am one of 'em! Check out the link in my signature (yeah I know I have to update the log...).





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Old 07-07-2008, 12:57 PM   #15003
DevilofSky
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hello guys..

i'm italian.. so... my questions are...

i've a dr650 like this

http://www.quietfisherman.com/Bike/003_3_small.jpg

1) there is the possibility to put on it .. i don't know the word in english... that thing for the wind.. because i'm going to have holidays with my dr..

2) how can i hang on the 2 sides luggages for the travel...
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Old 07-07-2008, 03:53 PM   #15004
PhL0aTeR
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stupid question..... if one were to be going down the road at 30-40 mph and hit the kill switch, then hit it again and a loud BANG (backfire) occurred, how bad is that for the bike?
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Old 07-07-2008, 04:22 PM   #15005
DevilofSky
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Quote:
Originally Posted by PhL0aTeR
stupid question..... if one were to be going down the road at 30-40 mph and hit the kill switch, then hit it again and a loud BANG (backfire) occurred, how bad is that for the bike?
this it was for me?

sorry i don't understand i'm not american
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Old 07-07-2008, 04:49 PM   #15006
pc1222
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Location: buffalo, ny
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Quote:
Originally Posted by DevilofSky
hello guys..

i'm italian.. so... my questions are...

i've a dr650 like this

http://www.quietfisherman.com/Bike/003_3_small.jpg

1) there is the possibility to put on it .. i don't know the word in english... that thing for the wind.. because i'm going to have holidays with my dr..

2) how can i hang on the 2 sides luggages for the travel...

I think the word you are looking for is windshield
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Old 07-07-2008, 04:49 PM   #15007
LukasM
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For you Corbin guys.....

From you guys who switched to the Corbin, does anyone still have a stock seat left over? I am looking for a cheap one, any condition is fine.

Cheers,
Lukas
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Old 07-07-2008, 04:56 PM   #15008
pc1222
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that is my 07 bought it from parabellum the best mod i ever did comes off with just four bolts if i want to go play in the dirt and on the hwy no wind blasting me just feel a small breeeeez could ride all day and paryt all night did 500 miles last week my ass was sore but the rest of me felt good . I dont even want to think how i would have felt with out it !
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Old 07-07-2008, 05:08 PM   #15009
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Quote:
Originally Posted by PhL0aTeR
stupid question..... if one were to be going down the road at 30-40 mph and hit the kill switch, then hit it again and a loud BANG (backfire) occurred, how bad is that for the bike?
All I'm going to say is this....................
In theory, what's happening is that the unburnt gasses that are making their way into the exhaust system unburnt, are being ignited when you turn your ignition back on and create the "backfire" when hot carbon/partial flame is making it's way out through the exhaust and igniting that unburnt mixture.
Again, in theory, there can be enough pressure build up within the exhaust system to force an exhaust valve open and slam it into your piston.

That being said...........my 97 hit the 50,000 mile mark without any engine damage occuring from the same practice. (it was a little old lady in a Subaru that took it out!)
Sure is fun waking up the cagers though!
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Old 07-07-2008, 05:26 PM   #15010
scootertrash
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Did the neutral switch thang..

Had some extra energy yesterday so I opened up the clutch case on the DR and checked the screws.

Turned off the gas and made sure the float bowl was dry:



Marked the clutch lever on the splined shaft before removing. Found out later it was unnecessary as the shaft will move when you R/R the clutch cover. Just make sure to move the lever as far back as you can by hand before putting it back on the shaft:



Laid the bike over on towels as I was too lazy to drain the new oil out of it:



Removed the footpeg with the mount:



Disconnected the master cylinder clevis pin and two springs, then swiveled the brake pedal down:



Note the washers stacked above and below the oil line, also the case bolt below and left of the oil line is the only one with a washer:



Finished removing the case bolts:



There's the neutral switch. I locktited the lower screw and removed the upper screw with a flat screwdriver and hammer as a chisel. It wasn't loose, but it came out real easy. I will eventually replace with a hex bolt, but for now, the lower screw is holding it in and is securely locktited.



Notice large oval hole below clutch basket, make sure you stuff a rag in it, because if a screw goes down there, you are in for a lot of work! Also, note the oil cooler line to the right, it has to be removed before the cover can come off. I did not have to remove the skidplate, just had to loosen it up for clearance. Tap on the cover and rotate it slightly as you lift it off.



It was probably a 1 to 2 hr job tops and a lot shorter when I go back in the next time with the hex bolt. No gaskets were needed and no oil was lost. Be careful to choke up on the ratchet handle when you tighten up the case bolts, you don't want to put too much torque on them. No issues, no leaks..
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Old 07-07-2008, 05:57 PM   #15011
DevilofSky
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Quote:
Originally Posted by pc1222
I think the word you are looking for is windshield
yes!! i can't find that here in italy...

there's some store/shop there where i can find it quite cheap?

ps. for the 2°question there is something?

thanks a lot!
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Old 07-07-2008, 06:20 PM   #15012
judjonzz
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There is a product called Dirt Bagz, soft bags with minimalist frames, available for the DR650

happy-trail.com makes aluminum panniers for the DR650.
http://happy-trail.com/category.aspx?categoryID=781

Eurotech Motorsports lists bags and mounts for the DR650SE.
http://www.eurotechmotorsports.com/f..._StartRow=1301

I am sure there others. I hope this helps.

Try a Google search on "DR650 saddlebag mounts".
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Old 07-07-2008, 06:35 PM   #15013
PhL0aTeR
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Quote:
Originally Posted by rivercreep
All I'm going to say is this....................
In theory, what's happening is that the unburnt gasses that are making their way into the exhaust system unburnt, are being ignited when you turn your ignition back on and create the "backfire" when hot carbon/partial flame is making it's way out through the exhaust and igniting that unburnt mixture.
Again, in theory, there can be enough pressure build up within the exhaust system to force an exhaust valve open and slam it into your piston.

That being said...........my 97 hit the 50,000 mile mark without any engine damage occuring from the same practice. (it was a little old lady in a Subaru that took it out!)
Sure is fun waking up the cagers though!
Well im glad.... lol.... cuz i did it today and nearly fell off the bike laughing so hard at how loud it was...... i figure next time someone is an idiot and talking on their cell phones ill hold the kill switch in for a few seconds then let it out KAPOWWWWWWWW
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Old 07-07-2008, 06:36 PM   #15014
DevilofSky
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what a prices!!


i can't
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Old 07-07-2008, 06:44 PM   #15015
adriftAK
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Location: Anchorage, AK
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Quote:
Originally Posted by speedwobble2
Taking the brace off the Safari tank takes all of about 30seconds and I have not found it a problem. The RHS of the tank covers nearly half of the length of the oil cooler and gives protection especially if you drop it.
The slim design of the 30l Safari tank makes moving around on the bike quite easy, you don't even notice it after a while. The only problem I had was when fitting it from new and had trouble getting the 2 rear bolts in but now that it has bedded in it's no trouble........I'm happy!
Installed my safari this weekend and had a similar experiance. Those 2 bolts gave me some fits initially but very easy install otherwise.
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