DisTech's DR650 rebuild

Discussion in 'Thumpers' started by DisTech, Dec 13, 2008.

  1. Reposado1800

    Reposado1800 Juicy J fan!

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    +1
    Kinda like walking by a chinese restaurant and suddenly deciding chinese would be great for dinner. This thread is killer. I love rebuild threads.:clap
  2. DisTech

    DisTech Been here awhile

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    Sep 3, 2008
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    643
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    Seattle
    Ok, I'll get Thor out again.

    Thanks.

    I'm in to deep. I spent about another hour on the throttle grip after that third picture. I doesn't look that bad now.

    After an hour you'll want another project bike. Thanks.
  3. DisTech

    DisTech Been here awhile

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    The stock wiring is mostly done, but before I close everything up I'll add the sensors for Vapor speedo/tach.

    Magnetic rotor bolt and speedo sensor.
    [​IMG]

    The instructions gave you four options for sensing spark for the tachometer.
    1. Wrap the red wire around a spark plug wire.
    2. Jam the red wire in the spade connector to the coil.
    3. Pop a spade connector to the coil out of its plastic shell and wrap 1.5" of stripped red wire around to top of the spade and shove it back in the shell.
    4. Wrap the red wire around a spark plug under the water seal.
    I chose option three.
    [​IMG]

    It looks ok installed but I feel 'dirty' making a connection like that.
    [​IMG]

    On the DR650 the temperature sensor can only go on the outer plug because the inner one is to far recessed. But the outer one is recessed too. That sensor was flat before I started.
    [​IMG]

    Temperture sensor installed.
    [​IMG]

    Plenty of wire for the speedo and tach, but the temp wire barely makes it.
    [​IMG]
  4. DisTech

    DisTech Been here awhile

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  5. Mezo

    Mezo Banned

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    Dirty ??, that`s rougher than a badgers arsehole man :huh

    Solder it & slip some heat shrink over it, come on dont slip now your doing such a fantastic job, looks the dogs gonads with that tank on now :evil

    Mezo.
  6. Kurlee

    Kurlee 2009: A Bike Odyssey

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    My god that looks good! Once I save up a little I'm going to go balls deep into a progect like that! Post up some more pics will ya? You should be able to finish that baby in a day or two :deal
  7. DisTech

    DisTech Been here awhile

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    <object width="425" height="344">


    <embed src="http://www.youtube.com/v/ZAskPOqN608&hl=en&fs=1" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="640" height="360"></object>
  8. Mezo

    Mezo Banned

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    Well done. :clap

    Its just such a shame the builds over :cry

    Or is it ? :evil

    Mezo.
  9. jtb

    jtb Long timer

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    Just found this and subscribed!

    Top job!:thumb :clap :bow :nod
  10. Mezo

    Mezo Banned

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    Your a bit slow there, its just been finished :evil

    Its been a staple of my evenings entertainment for weeks.


    Mezo.
  11. jtb

    jtb Long timer

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    Yeah? Well you didn't tell me about it!:baldy

    Besides, I haven't seen a photo of the finished project yet:nod So I'm all :ear :D
  12. Rusty Rocket

    Rusty Rocket Life behind "Bars"

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    Left CT, moved to TN

    :lol3 Most DR650's I know of are never finished.
  13. RearView

    RearView Caveman Philosopher

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    Well done!!!!!!!!!!!!!:clap

    I had the satisfaction of reassembling the top end from a complete teardown on my DR. It runs, so that's good. Been watching. Mucho enjoyo. Inspiring for a project of my own to make a DR mine from the frame up.
  14. Watson

    Watson Been here awhile

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    It is ALIVE!

    ...shit, I've been poking my nose in here just about everyday. Now I see this it's alive post, and I'm at work....whatever's in that post, I can't see 'cause they block a lot of content via WebSense.
  15. DisTech

    DisTech Been here awhile

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    Yea you're right, unacceptable! But, I think I'll check to see if the Vapor works before I make a permanent connection.

    Thanks, I'm still waiting on the seat and fabbing something for the headlight and windscreen is going to take me a bit.

    Thanks Mezo, jtb and Rusty, not done yet!

    Thanks, looking forward to your rebuild thread!

    It's a video clip of the second startup. I just couldn't wait to see if I put the engine back together right (it appears as though I did). I need to adjust the carb still.
  16. DisTech

    DisTech Been here awhile

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    In the video the choke is on and the bike is pretty cold. Not shown in the video, as the bike warms up the idle climbs until I push the choke in which drops the idle but it's still to fast. It's also running very hot (exhaust header was red, scared the poop out of me when I saw it!) and with the choke in it backfires. The backfiring made me think it was a timing problem which had me worried that I had put something together wrong since CDI handles timing. I set the valves, but they were minimally off. The plugs were out while setting the valves and had a bit of black soot on them. I googled around looking for DR650 backfiring issues and there were a couple that were relevant (among the hundreds about backfiring during deceleration). The threads said if you are running too rich fuel can detonate in the exhaust.

    Clues:
    1. idles to fast
    2. running hot
    3. backfire in exhaust
    4. soot on plugs
    Seems obvious, it's running to rich. According to the HS40 tuning manual the idle circuit must be tuned first. Turn the pilot screw in a half turn at a time until the idle slows or becomes irregular. I got all the way down to 1/4 turn out and she was still idling to fast and backfiring. The TM40 comes from ProCycle setup for a DR650 that matches my airbox, filter and exhaust. Adjusting the pilot screw to the bottom of the range had me worrying again that I had put something together wrong and it wasn't the new carb. So, I put the stock carb and tank back on and fired it up. It ran nice and smooth, low idle and no backfiring, YAY! Continuing with the TM40 idle circuit tuning, I put the #20 pilot jet in and set the pilot screw a 2 turns out. That's where I'm at now, hopefully make some progress this weekend.

    TM40 top.
    [​IMG]

    TM40 top off.
    1. Needle clip in 3rd position from the top.
    [​IMG]

    TM40 bottom.
    [​IMG]

    TM40 bottom off.
    1. Main jet 150.
    2. Pilot jet 22.5.
    3. Pilot screw 1/4 turn out.
    [​IMG]

    Range of pilot and main jets included in ProCycle kit.
    [​IMG]
  17. muddriller

    muddriller Been here awhile

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    Could be worse. Didnt have any scotch tite connectors around to use?
  18. DisTech

    DisTech Been here awhile

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    A bit of a frustrating day trying to tune the idle circuit. I adjusted the pilot screw half turn at a time down to the minimum 1/4 turn thru 22.5, 20 and 17.5 pilot jets. The light bulb finally came on for me when I realized that the pilot screw wasn't changing anything. My idle circuit was not working. I took the bottom end of the TM40 all apart and blasted carb cleaner through all of the jets and passageways (especially the idle circuit) and reassembled back to ProCycle defaults with the 22.5 pilot jet and the pilot screw at 3 turns out. For the record, I never ran the TM40 without a fuel filter and the inside of it was spotless clean. I didn't find any blockage or particles, but when I fired the bike up it ran nice and smooth, no backfiring. Also 3 turns out for the pilot screw appears to be the sweet spot. So the default settings from ProCycle are on the money. The clues that lead me to think it was running rich in the beginning are confusing. Maybe the sooted plugs were from running with the choke on, I don't know. With the idle circuit operating as it should I can proceed with the rest of the carb tuning!
  19. DisTech

    DisTech Been here awhile

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    The TM40 is set with the ProCycle defaults except for the needle clip. I moved it to the second position from the top (supposed to be better MPG).
    [​IMG]

    Buttoning up the wiring for the back end and tightened and recabled the TM40.
    [​IMG]
  20. DisTech

    DisTech Been here awhile

    Joined:
    Sep 3, 2008
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    643
    Location:
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    I took the inner fender off so I need a holder and light for the license plate. This is a bolt on solution from from Kientech.
    [​IMG]

    Wired so I can go back to stock without cutting any wires.
    [​IMG]

    Didn't really want an additional brake light but it serves as the plate light too.
    [​IMG]