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Old 10-10-2011, 06:55 AM   #55351
shu
...
 
Joined: Feb 2010
Location: Colorado
Oddometer: 1,053
Quote:
Originally Posted by fishbulb View Post
hi guys... where do you get the stick on side cover (case) protectors?
Perry, at AMP, makes them. He's got a nice little small business going and has been making them for few years now.

http://www.motorcycleproducts.org/En...n-frameset.htm

...........shu
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Old 10-10-2011, 10:19 AM   #55352
vintagespeed
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Joined: May 2011
Location: Rancho Cucamonger, CA
Oddometer: 1,799
Quote:
Originally Posted by 955616846 View Post
....the heaviest spring specific to this shock is 6.3kg/mm from Eibach. Beyond that you'd be looking at adaptor rings (easy for a competent machinist) to mount anything heavier.
http://www.cannonracecraft.com/

YEAR MODEL FK SPRG RATES SHK SPRG RATES
2001-2005 DRZ 400 43510 .36,.38,.40,.42,.44, .46.48,.50,.52, .54 SHOWA 3.6-7.4
1999-2000 DRZ 400 44510 SPECIAL ORDER ONLY SHOWA 3.6-7.4
2000-2005 DRZ 400E 43510 .36,.38,.40,.42,.44, .46.48,.50,.52, .54 SHOWA 3.6-7.4
2000-2004 DRZ 400S 43520 SPECIAL ORDER ONLY SHOWA 3.6-7.4


takes them 5days to build custom springs, if needed.
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TAT-2013: http://www.advrider.com/forums/showthread.php?t=913898
SoCal_NoDak-2012: http://www.advrider.com/forums/showthread.php?t=829203
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Old 10-10-2011, 11:23 AM   #55353
Adv Grifter
on the road o'dreams
 
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Joined: Jan 2010
Location: Passing ADV Stalkers in California
Oddometer: 6,128
Quote:
Originally Posted by PHILinFRANCE View Post
This thread SUCKS
... on your bicycle now mate! Better get working on your Morocco report. We're all "ears" here!

I trust you've been following Colebatch's report ... best Maroc report I've ever seen. His hand built $$$$$ BMW had shite-loads of problems ... I hope your DR is well prepped so you can fly the DR flag high! NO BREAKDOWNS! (flats are OK)

Adv Grifter screwed with this post 10-10-2011 at 01:26 PM
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Old 10-10-2011, 12:08 PM   #55354
DRinda505
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Joined: Jan 2007
Location: Land Of Enchantment
Oddometer: 407
Intermittent Starter Issues

I have a problem with electric start not always working, I'm suspecting the neutral start switch.
Here are the details.
I have bypassed and removed the kickstand safety switch and the clutch safety switch.
When the starter doesn't crank...
I turn on the key, and all electronics (lights on...) work.
The starter does not turn over the engine, no clicks or dimming of the headlight.
I can pull the plastic cover on the starter relay, and jumper the high current relay contacts to crank the engine, but it seems like no ignition spark.
After a couple of times doing this, the starter switch will start to work, and the bike fires right up.
It will continue to work normal for a few days, then reverts to the no crank condition, and I can then repeat the process.
I have a new starter relay here, but have not swapped it yet.
My suspicion is something loose inside the cover on the neutral switch?
Do these symptoms makes sense for this?
I know I'm being trouble shooting lazy here, but I'm hoping to use this wealth of experience to solve my problem.
Thanks for the suggestions.

DRinda505
DRZ front forks
DRZ rear shock with home made lower shock mount & dogbone linkage
IMS tank
skid plate
lowered foot pegs
open airbox w/ FCRMX carb
FMF power bomb header & Q4 silencer
Self made bar risers, seat, & panniers
wanting the procycle big valve cylinder head this winter.
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Old 10-10-2011, 12:14 PM   #55355
plugeye
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Joined: May 2007
Location: Garland, Texas
Oddometer: 3,904
you eliminated the kickstand switch, so disregard the neutral switch.
check your kill switch, could be dirty
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Old 10-10-2011, 01:16 PM   #55356
Klay
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Joined: Nov 2005
Location: right here on my thermarest
Oddometer: 102,756
Does the flange on the front sprocket go in or out?
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Old 10-10-2011, 01:23 PM   #55357
Adv Grifter
on the road o'dreams
 
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Joined: Jan 2010
Location: Passing ADV Stalkers in California
Oddometer: 6,128
Quote:
Originally Posted by DRinda505 View Post
I have a problem with electric start not always working, I'm suspecting the neutral start switch.
Here are the details.
I have bypassed and removed the kickstand safety switch and the clutch safety switch.
When the starter doesn't crank...
I turn on the key, and all electronics (lights on...) work.
The starter does not turn over the engine, no clicks or dimming of the headlight.
I can pull the plastic cover on the starter relay, and jumper the high current relay contacts to crank the engine, but it seems like no ignition spark.
After a couple of times doing this, the starter switch will start to work, and the bike fires right up.
It will continue to work normal for a few days, then reverts to the no crank condition, and I can then repeat the process.
I have a new starter relay here, but have not swapped it yet.
My suspicion is something loose inside the cover on the neutral switch?
Do these symptoms makes sense for this?
I know I'm being trouble shooting lazy here, but I'm hoping to use this wealth of experience to solve my problem.
Thanks for the suggestions.
Couple things to check:
1. Double Check you wiring on the side stand and clutch safety switch mods you did. Make sure nothing is shorting or grounding out causing a no start.

2. Spray some WD40 into Kill switch and Start button. Work it in there and operate the switches. Sometimes can help ... can't hurt.

3. If it won't start ... put the bike in 2nd gear and just push it forward a bit, just turning the engine a few degrees. Does it start after that?
If this is what's happening and a slight rotation allows it to start then the starter motor brushes may need dressing up and lubed ... or new brushes.
Water gets in there and can screw things up.

Could be the relay ... not sure how to check it.

Good luck.
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Old 10-10-2011, 02:14 PM   #55358
skysailor
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Joined: Oct 2007
Location: Kenora, Canada
Oddometer: 3,645
Changes 2002 to New

Buying a 2002 DR650. Can remain without one for no longer. Is there somewhere I can find a list of up dates/differences between that and a new one? Just stuff that "matters". Thanks.
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Old 10-10-2011, 02:24 PM   #55359
Dyno
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Joined: Nov 2006
Location: Bottom of Lake Huron
Oddometer: 1,871
Quote:
Originally Posted by skysailor View Post
Buying a 2002 DR650. Can remain without one for no longer. Is there somewhere I can find a list of up dates/differences between that and a new one? Just stuff that "matters". Thanks.
The color changed, and they added "bold new graphics".
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Old 10-10-2011, 02:27 PM   #55360
vintagespeed
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Joined: May 2011
Location: Rancho Cucamonger, CA
Oddometer: 1,799
Quote:
Originally Posted by skysailor View Post
Buying a 2002 DR650. Can remain without one for no longer. Is there somewhere I can find a list of up dates/differences between that and a new one? Just stuff that "matters". Thanks.
second gear was changed in '06 to stop them blowing up...
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530EXCR and a bunch of 2 strokes that you dont want to read about. :)

TAT-2013: http://www.advrider.com/forums/showthread.php?t=913898
SoCal_NoDak-2012: http://www.advrider.com/forums/showthread.php?t=829203
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Old 10-10-2011, 02:35 PM   #55361
EvanADV
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Joined: Jul 2010
Location: Joplor, NC
Oddometer: 1,337
Quote:
Originally Posted by skysailor View Post
Buying a 2002 DR650. Can remain without one for no longer. Is there somewhere I can find a list of up dates/differences between that and a new one? Just stuff that "matters". Thanks.
Paper base gasket.
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Old 10-10-2011, 02:44 PM   #55362
ag_streak
Tiene Ruta Cuarenta?
 
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Joined: Aug 2006
Location: Heart of the Chattahoochee
Oddometer: 3,201
Boy, can't anyone use a nice seat cover and foam?

http://www.advrider.com/forums/showthread.php?t=731585

Not one reply!
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Old 10-10-2011, 02:51 PM   #55363
BergDonk
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Joined: Nov 2010
Location: Snowy Mountains Oz
Oddometer: 3,818
Quote:
Originally Posted by Klay View Post
Does the flange on the front sprocket go in or out?
For a 520 chain it goes to the outside.
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BergDonk's DR650 BergDonk's XT1200Z
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Old 10-10-2011, 03:14 PM   #55364
Mongle
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Joined: Dec 2009
Location: North Carolina Y'all
Oddometer: 3,156
Quote:
Originally Posted by Rumlover View Post
First, Congrats on the new bike!
I won't even attempt explaining carb theory (probabaly better for all), But I will tell you that opening up the air box and exhaust will result in a lean condition. You may get away with pulling the snorkel, depending on your altitude, but anything much more will result in a lean conditon. In fact on the DR the change can be rather dramatic. My own experience with jetting and opening up the air box hole resulted in some pretty wild swings until I got the jetting and new hole size to match up.

But feel free to experiment away, the simplicity of the DR kind of encourages it. Good luck!
Funny, everyone has a theory but I haven't seen one person actually put an air/fuel meter on the bike and try diffrent things. Soooo.....

I am in the process on installing an air/fuel meter on my DR. Waiting on my welder to install the bung in the mid pipe. I wont be able to give air/fuel for the stock muffler just because it seemed stupid to go through the trouble to weld a bung in the stock muffler then take it off to replace it.... I put a Yoshimura midpipe and R3 silencer. Plan on getting readings from the stock carb settings...re-jetting (if needed) and I will pull the snorkle just for shits and grins to see if it makes a change. I will be using an Innovate LM1 wide band air/fuel meter. Nice thing is it records rpm/ air fuel, manifold pressure, and other stuff if I want. Record then go back and look so I will be able to give a little run down of what I saw.
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Old 10-10-2011, 03:16 PM   #55365
Klay
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Joined: Nov 2005
Location: right here on my thermarest
Oddometer: 102,756
Quote:
Originally Posted by BergDonk View Post
For a 520 chain it goes to the outside.

Good, thanks, that's the way I installed it.
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