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Old 01-23-2013, 08:14 PM   #73141
ER70S-2
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Location: SE Denver-ish
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Quote:
Originally Posted by shaddix View Post
Wow yeah all the wires are burned up and frayed. I unplugged something now the headlight won't come on anymore. I will have to read up. Looks like this is gonna suck lol. I was about to sell it too.


Ugh wiring harness 300 bucks really? I think I should take it to a dealer
Have there been any wiring modifications to your bike? The dealer will be glad to see you.

Quote:
Originally Posted by shu View Post
Smoke? Under the tank? I've smelled that before. In this case it was from an F650 Dakar. We put it out with our water bottles but not in time to save the bike.


somewhere in Uzbekistan


http://www.advrider.com/forums/showt...r+2010&page=15

Time to get some help from someone who knows wiring.


..............shu
Holy sheeeeeeeeeeeeeeettttttttttttt!!!!! My heart would stop if I saw that mess anywhere near home. But somewhere in Uzbekistan!! Bimmers suck. Glad it wasn't on a DR, my nightmares would start tonight.

I am, however, on shedule to leave for Kalifornia on Friday.
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"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 01-23-2013, 09:05 PM   #73142
Adv Grifter
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Location: Passing ADV Stalkers in California
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Originally Posted by TIGERRIDER007 View Post
Do these last for a while? I'm looking hard at those Mezteler Unicross tires too...thanks!
"Last" is a relative term. For an Off Road tire they hold up very well. But if you run them at high speed on pavement ... they'll probably be gone in less than 2,000 miles.

I'd bet on the T-63 going further for riding more pavement. But the Gritty is far better performing off road. Guys race on these tires. The real deal ... but not really ideal for pavement. I would consider a Gritty front over the T-63. Fronts don't wear out like a rear ... so a front Gritty will work well until you flat spot it on pavement.
At that point ... it's junk. The front is the important tire off road ... especially on the heavy DR650.

The Metzelers are Excellent too!

You can't have everything in ONE tire ....
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Old 01-23-2013, 09:14 PM   #73143
Adv Grifter
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Location: Passing ADV Stalkers in California
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Quote:
Originally Posted by shaddix View Post
Wow yeah all the wires are burned up and frayed. I unplugged something now the headlight won't com on anymore. I will have to read up. Looks like this is gonna suck lol. I was about to sell it too


Ugh wiring harness 300 bucks really? I think I should take it to a dealer
Shop hourly rate varies ... probably between $65 to $90 per hour. Sorting out burnt out wiring harness is very labor intensive ... especially if they give the job to the young apprentice .
I'd guess maybe 8 hours of shop time to re-wire the bike?

You need to find a good friend who likes Beer ... and also knows how to read a wiring harness and use a VOM (volt-Ohm meter) It's not so bad for an experienced electrical guy.

If not too many of your wires are burnt ... just go back in and solder in replacement wires. Try to color match and used same gauge wire. Also, you've got to find what the original problem was ... or the same thing will happen again.

Good luck!
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Old 01-23-2013, 09:48 PM   #73144
shaddix
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Quote:
Originally Posted by Adv Grifter View Post
Shop hourly rate varies ... probably between $65 to $90 per hour. Sorting out burnt out wiring harness is very labor intensive ... especially if they give the job to the young apprentice .
I'd guess maybe 8 hours of shop time to re-wire the bike?

You need to find a good friend who likes Beer ... and also knows how to read a wiring harness and use a VOM (volt-Ohm meter) It's not so bad for an experienced electrical guy.

If not too many of your wires are burnt ... just go back in and solder in replacement wires. Try to color match and used same gauge wire. Also, you've got to find what the original problem was ... or the same thing will happen again.

Good luck!
I make 18/hr. New harness is like 300 bucks. Best bet is to just buy and replace it myself?
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Old 01-23-2013, 09:51 PM   #73145
neo1piv014
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Quote:
Originally Posted by shaddix View Post
I make 18/hr. New harness is like 300 bucks. Best bet is to just buy and replace it myself?
Can we get a picture of what your wires look like? If they're all totally trashed, then yeah, you might have to just buy a new wiring harness (check ebay and local wrecker yards first), but if it's only one or two problem wires, soldering and shrinking is going to be fine.
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Old 01-23-2013, 10:23 PM   #73146
neo1piv014
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In between studying for some IT exams at work, I finally got the top off my carb again, which would be vastly easier if the seat, side panels, tank, throttle cables, and choke cable didn't have to come off with it. Thanks to all the helpful folks on here, I realized that my white spacer was in the completely wrong place, and I had an unnecessary washer shimming things up as well. I pushed the spacer up to where I had the clip (position 3), made sure everything was snug, and set the washer aside. I put everything back together and let it idle for about 5-7 minutes in the garage just to get up to a temp where it didn't need the choke to maintain smooth idle.
After that, I started playing with the throttle position to see if there were any quickly detectable rough spots. The thing revved like it wanted to be a sport bike and sounded much, much better. There didn't seem to be nearly as much of a hesitation in the throttle, either. Assuming that this fixes the bogging, surging, and extremely poor mileage I've been getting, I'll call it a success. I'm definitely expecting to see some mileage improvements, since the spacer was essentially simulating a needle with the clip at the 75th position or so

Here's to hoping I'm done posting about carbs except to say "hey guys, I finally ordered that TM40"

my specs:
-12,500 miles on carb and engine
- K&N air filter
- Stock exhaust
- Cut airbox
- Non-USA OEM needle from motolab with clip on third position
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Old 01-24-2013, 02:14 AM   #73147
BergDonk
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Electrical Repairs

It can be difficult to get replacement metric smoke because its so rarely needed, but the Imperial Lucas product is readily available at your local British bike or car shop. It just needs to be suitably massaged to adapt it to the metric application.

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Old 01-24-2013, 02:20 AM   #73148
1989THEARK
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Location: Moreno Valley Ca
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You make 18 an hour and will be paying 600 dollars if you dont find the problem the FIRST time.

i've replaced a few wiring harnesses myself in cars.

if it turns out the charging system is what melted the wiring harness in the first place you run the risk of not only burning a few wires.

but setting the bike on fire.

your choice. But if you set the bike on fire. can i have your foot pegz?

Quote:
Originally Posted by shaddix View Post
I make 18/hr. New harness is like 300 bucks. Best bet is to just buy and replace it myself?
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Old 01-24-2013, 06:53 AM   #73149
shaddix
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Quote:
Originally Posted by neo1piv014 View Post
Can we get a picture of what your wires look like? If they're all totally trashed, then yeah, you might have to just buy a new wiring harness (check ebay and local wrecker yards first), but if it's only one or two problem wires, soldering and shrinking is going to be fine.
The harness is all melted together in two places, I can take pics this weekend





Quote:
Originally Posted by 1989THEARK View Post
You make 18 an hour and will be paying 600 dollars if you dont find the problem the FIRST time.

i've replaced a few wiring harnesses myself in cars.

if it turns out the charging system is what melted the wiring harness in the first place you run the risk of not only burning a few wires.

but setting the bike on fire.

your choice. But if you set the bike on fire. can i have your foot pegz?
Yeah I'm just gonna take it to a dealer ._.
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Old 01-24-2013, 08:14 AM   #73150
Carl Childers
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Location: Northern New Mexico
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Quote:
Originally Posted by BergDonk View Post
It can be difficult to get replacement metric smoke because its so rarely needed, but the Imperial Lucas product is readily available at your local British bike or car shop. It just needs to be suitably massaged to adapt it to the metric application.

Ah Lucas, Prince of darkness!
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Old 01-24-2013, 08:53 AM   #73151
Rusty Rocket
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Location: Trying to leave CT
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Quote:
Originally Posted by TIGERRIDER007 View Post
Do these last for a while? I'm looking hard at those Mezteler Unicross tires too...thanks!
I ride a mix of true offroad trails and gravel roads. 80 -90% And the rest tar. I typically trailer my DR650 to the area I'm gonna ride. I get about 2500 miles out of the Kenda Trakmaster rear and maybe 3500-4K from the ED-03.

Quote:
Originally Posted by shaddix View Post
Best bet is to just buy and replace it myself?
I also had a wire harness fire. ended up putting in a used harness. (check ebay or other DR forums first) It was not to hard, but a bit of advice. I started at one end of the bike and worked my way to the other end unhooking and re-connecting as I went, so I could replicate the routing, which is important because of things like where the tank goes etc. best of luck. you can do it!
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Old 01-24-2013, 10:10 AM   #73152
Richguzzi
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Quote:
Originally Posted by shaddix View Post
The harness is all melted together in two places, I can take pics this weekend

Yeah I'm just gonna take it to a dealer ._.

Bring plenty of lube....

You should at least investigate whether those two spots are completely melted together or the sheathing is just melted all up due to one or two wires overheating. Could be an easy and far cheap solution to splice in some new wires and connections.
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Old 01-24-2013, 12:13 PM   #73153
Rusty Rocket
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There are several DR650 wire harnesses on ebay. Ex: http://www.ebay.com/itm/Wiring-harne...020ca2&vxp=mtr
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Old 01-24-2013, 03:05 PM   #73154
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Originally Posted by shaddix View Post
I make 18/hr. New harness is like 300 bucks. Best bet is to just buy and replace it myself?
You have comp on your insurance? Fire is a covered loss in most policies. The original individual part that failed likely won't be covered but all the resulting damage would be.
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Old 01-24-2013, 03:13 PM   #73155
acesandeights
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Quote:
Originally Posted by sic semper tyrannis View Post
you have comp on your insurance? Fire is a covered loss in most policies. The original individual part that failed likely won't be covered but all the resulting damage would be.
+1
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