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Old 12-01-2012, 10:20 PM   #71536
badweatherbiker
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Joined: Dec 2007
Location: North Florida
Oddometer: 702
Some of you may remember I picked up a 2003 DR650 a little over a month ago and after a couple weeks of throttle hesitations and extreme surging I decided to clean the carb and have a look see at the the jetting inside. Well one thing led to another and next thing I know the bike is not rideable and I am borrowing cars to get to work.
i called up Derek and had a carb rebuild kit and some various jets and a needle on its way and got it all installed this past week and finally finished it up just in time for a ride today.
although it still surges and occasionally sputters on a sustained freeway ride it runs much better.
i am still gonna try to troubleshoot it to get it right but at lest I can ride it now.
To everyone that helped me figure out some of the issues I really appreciate the help and big thanks to Derek for putting up with a whole lot of emails with endless questions.
I did find an exhaust leak going into the muffler that will need to be fixed and three are a couple other things I need to get it right but at least I am on the right path!
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Old 12-01-2012, 10:33 PM   #71537
Adv Grifter
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Joined: Jan 2010
Location: Passing ADV Stalkers in California
Oddometer: 6,128
Quote:
Originally Posted by badweatherbiker View Post
Some of you may remember I picked up a 2003 DR650 a little over a month ago and after a couple weeks of throttle hesitations and extreme surging I decided to clean the carb and have a look see at the the jetting inside. Well one thing led to another and next thing I know the bike is not rideable and I am borrowing cars to get to work.
i called up Derek and had a carb rebuild kit and some various jets and a needle on its way and got it all installed this past week and finally finished it up just in time for a ride today.
although it still surges and occasionally sputters on a sustained freeway ride it runs much better.
i am still gonna try to troubleshoot it to get it right but at lest I can ride it now.
To everyone that helped me figure out some of the issues I really appreciate the help and big thanks to Derek for putting up with a whole lot of emails with endless questions.
I did find an exhaust leak going into the muffler that will need to be fixed and three are a couple other things I need to get it right but at least I am on the right path!
Kudos to Derek!
If you're still getting sputters ... I'm guessing WATER in fuel tank. Have you ever flushed it out? Have you pulled the petcock out of the tank and cleaned it? I assume you have checked the little white intake fuel filter on the carb too?

Other than that ... I can only think an OPEN air box ... like side cover OFF.
(not good) or leaky rubber manifolds from air box to Carb or going into intake manifold. Or ... something plugged on Carb that should not be plugged ...

Keep looking and testing ... one thing at a time. You'll track it down.
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Old 12-01-2012, 10:38 PM   #71538
Adv Grifter
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Location: Passing ADV Stalkers in California
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Quote:
Originally Posted by sunthechip View Post
My chain guide is worn through and the chain has left 2 shallow gouges in the swingarm. Is this a serious problem? Will the gouges cause any problems or inhibit the function of the replacement chain guide?

Should be OK. But DO NOT ride it anymore like that. Install a new Rubber
Swing Arm Chain Slider. (chain guide is the plastic white thing under your rear sprocket). while you're at it, pull rear wheel off. Check out the swing arm for looseness (left to right) You may need to pull out the BIG swingarm bolt, check bearings and re-grease. Be careful .. those are in there very tight. Use proper wrench and breaker bar. When you put it back be sure to Torque to spec. Bearings are probably OK ... but might be worth a look if any roughness or lateral slack is found.
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Old 12-01-2012, 10:38 PM   #71539
badweatherbiker
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Joined: Dec 2007
Location: North Florida
Oddometer: 702
Quote:
Originally Posted by Adv Grifter View Post
Kudos to Derek!
If you're still getting sputters ... I'm guessing WATER in fuel tank. Have you ever flushed it out?
This is possible, its been sitting on my workbench under a shelter outside for a month, condensation?
Have you pulled the petcock out of the tank and cleaned it? not yet
I assume you have checked the little white intake fuel filter on the carb too? I did do that!

Other than that ... I can only think an OPEN air box ... like side cover OFF. top of the airbox is cut for the procycle jet kit
(not good) or leaky rubber manifolds from air box to Carb or going into intake manifold. Or ... something plugged on Carb that should not be plugged ...

Keep looking and testing ... one thing at a time. You'll track it down.
Thanks for all the suggestions!
__________________
1996 Kawasaki KZ1000P (currently being rebuilt)
World class nutritional supplements, weight loss, meal replacement shakes, quality energy drinks, pre and post workout supplements!
Earn extra income, become a distributor or just purchase:
Advocare products-www.advocare.com/12084065
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Old 12-01-2012, 11:23 PM   #71540
smilin jack
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Joined: May 2008
Location: Lebanon Oregon
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Swing Arm

Quote:
Originally Posted by Adv Grifter View Post
Should be OK. But DO NOT ride it anymore like that. Install a new Rubber
Swing Arm Chain Slider. (chain guide is the plastic white thing under your rear sprocket). while you're at it, pull rear wheel off. Check out the swing arm for looseness (left to right) You may need to pull out the BIG swingarm bolt, check bearings and re-grease. Be careful .. those are in there very tight. Use proper wrench and breaker bar. When you put it back be sure to Torque to spec. Bearings are probably OK ... but might be worth a look if any roughness or lateral slack is found.
Tore open the swing-arm today (2006 DR650se) to grease the swing arm bearings. Yes they needed grease and the bearing were OK.






Put axle grease in a livestock shot syringe and squirted it in on the needle bearings. Worked quite well.

The chain slider was well worn and a new one is on order from PC along with the new rear cushion bearings. The most forward bearing there was loose and the others had a little wiggle so got "the kit" coming.

Will be taking the truck to work for a few days.

Dave

smilin jack screwed with this post 12-02-2012 at 02:57 PM
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Old 12-02-2012, 01:04 AM   #71541
NordieBoy
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Joined: Dec 2006
Location: Kiwiland
Oddometer: 7,132
Quote:
Originally Posted by sunthechip View Post
hmmmmm.... I think my corbin seat is too low for me or something. My butt feels like it wants to go more forward with the corbin than I can remember with the stock.....
Time to get busy then...
http://sports.nelson.geek.nz/motorsp...ing/index.html

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Old 12-02-2012, 01:15 AM   #71542
NordieBoy
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Joined: Dec 2006
Location: Kiwiland
Oddometer: 7,132
Quote:
Originally Posted by macrae85 View Post
Ahh,moral in my madness......Continental have now released 17" TKC80's tyres in supermoto sizes
120/70 (f) 150/70 (r)........ideal for the 2nd half of my AZ -Argentina trip!
I knew this 17" set up was ideal......only need 1 spare tube! :)
I ran a 150x17 on my Nordwest back in 2005...
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Old 12-02-2012, 06:12 AM   #71543
planemanx15
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Joined: Dec 2009
Location: Long Island, NY
Oddometer: 1,007
Its back!!!!! After 40 days (who's counting ) without my rear wheel, I finally got it back from Warp 9. Put a 150/70-17 Shinko 712 on it... Now how do I ride this thing?

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Old 12-02-2012, 07:53 AM   #71544
Rumlover
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Joined: Sep 2010
Location: Utah
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Quote:
Originally Posted by badweatherbiker View Post
Some of you may remember I picked up a 2003 DR650 a little over a month ago and after a couple weeks of throttle hesitations and extreme surging I decided to clean the carb and have a look see at the the jetting inside. Well one thing led to another and next thing I know the bike is not rideable and I am borrowing cars to get to work.
i called up Derek and had a carb rebuild kit and some various jets and a needle on its way and got it all installed this past week and finally finished it up just in time for a ride today.
although it still surges and occasionally sputters on a sustained freeway ride it runs much better.
i am still gonna try to troubleshoot it to get it right but at lest I can ride it now.
To everyone that helped me figure out some of the issues I really appreciate the help and big thanks to Derek for putting up with a whole lot of emails with endless questions.
I did find an exhaust leak going into the muffler that will need to be fixed and three are a couple other things I need to get it right but at least I am on the right path!
It's good to hear Derek was willing to help so much. I always like to hear about good customer service!

But good on you for being willing to jump in and do the work. You will figure the rest of the issues out, and with all the knowledge/experience you are gaining will be able to help the next guy out.
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Old 12-02-2012, 08:00 AM   #71545
Mambo Dave
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Joined: Oct 2011
Location: 11 ft. AMSL
Oddometer: 5,189
Quote:
Originally Posted by badweatherbiker View Post
Some of you may remember I picked up a 2003 DR650 a little over a month ago and after a couple weeks of throttle hesitations and extreme surging I decided to clean the carb and have a look see at the the jetting inside. Well one thing led to another and next thing I know the bike is not rideable and I am borrowing cars to get to work.
i called up Derek and had a carb rebuild kit and some various jets and a needle on its way and got it all installed this past week and finally finished it up just in time for a ride today.
although it still surges and occasionally sputters on a sustained freeway ride it runs much better.
i am still gonna try to troubleshoot it to get it right but at lest I can ride it now.
Now that you've got fuel flowing through it - SeaFoam, man, SeaFoam. It will clean it for you. Probably the easiest 'fix' for motorcycles that have sat ever was.
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Old 12-02-2012, 10:10 AM   #71546
mrprez
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Joined: Apr 2008
Location: Mobile, Al
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Quote:
Originally Posted by planemanx15 View Post
Its back!!!!! After 40 days (who's counting ) without my rear wheel, I finally got it back from Warp 9. Put a 150/70-17 Shinko 712 on it... Now how do I ride this thing?
The only way you can. Balls to the wall.
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Old 12-02-2012, 10:10 AM   #71547
805gregg
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Joined: Jan 2006
Location: Ojai, Ca
Oddometer: 1,531
Quote:
Originally Posted by JagLite View Post
I have stock, Corbin, and Seat Concepts.
I find the Seat Concepts the most comfortable of the three.
Corbin is nice and wide but rather hard for my boney butt.
Stock is just plain uncomfortable to me for longer than 20 minutes.
Sargent for me, an all day seat.
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Old 12-02-2012, 11:38 AM   #71548
sunthechip
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Joined: May 2012
Oddometer: 123
Quote:
Originally Posted by Adv Grifter View Post
Should be OK. But DO NOT ride it anymore like that. Install a new Rubber
Swing Arm Chain Slider. (chain guide is the plastic white thing under your rear sprocket). while you're at it, pull rear wheel off. Check out the swing arm for looseness (left to right) You may need to pull out the BIG swingarm bolt, check bearings and re-grease. Be careful .. those are in there very tight. Use proper wrench and breaker bar. When you put it back be sure to Torque to spec. Bearings are probably OK ... but might be worth a look if any roughness or lateral slack is found.
I was researching the torque specs and I came across this: http://www.advrider.com/forums/showthread.php?t=466791 - Apparently the lower shock bolt was stripping out when set to factory torque specs. Can you comment on the validity of this, and would it be a good idea to go with his recomendation of limiting the torqueing of the lower shock bolt on the current gen DR650 to 37Nm / 3.7 kg-m and adding blue locktite to the threads?
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Old 12-02-2012, 11:42 AM   #71549
sunthechip
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Joined: May 2012
Oddometer: 123
Quote:
Originally Posted by smilin jack View Post
Tore open the swing-arm today (2006 DR650se) to grease the swing arm bearings. Yes they needed grease and the bearing were OK.

Put axle grease in a livestock shot syringe and squirted it in on the needle bearings. Worked quite well.

The chain slider was well worn and a new one is on order from PC along with the new rear cushion bearings. The most forward bearing there was loose and the others had a little wiggle so got "the kit" coming.

Will be taking the truck to work for a few days.

Dave
I'll be taking the pedal bike to work for a few days ...
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Old 12-02-2012, 12:54 PM   #71550
motolab
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Joined: Feb 2006
Oddometer: 2,403
Quote:
Originally Posted by badweatherbiker View Post
Some of you may remember I picked up a 2003 DR650 a little over a month ago and after a couple weeks of throttle hesitations and extreme surging I decided to clean the carb and have a look see at the the jetting inside. Well one thing led to another and next thing I know the bike is not rideable and I am borrowing cars to get to work.
i called up Derek and had a carb rebuild kit and some various jets and a needle on its way and got it all installed this past week and finally finished it up just in time for a ride today.
although it still surges and occasionally sputters on a sustained freeway ride it runs much better.
I'm glad to hear!
Quote:
i am still gonna try to troubleshoot it to get it right but at lest I can ride it now.
What's left must either be jetting or fuel supply related. Is the fuel filter inside the inlet elbow clean? Have you tried it with the gas cap removed (maybe the vent is clogged)?
Quote:
To everyone that helped me figure out some of the issues I really appreciate the help and big thanks to Derek for putting up with a whole lot of emails with endless questions.
Not a problem and you're very welcome.

Regards,

Derek
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