DR650 Engine / Transmission Rebuild

Discussion in 'Thumpers' started by rch10007, Mar 14, 2012.

  1. ADV8

    ADV8 Taumarunui..Darwin..

    Joined:
    Nov 10, 2007
    Oddometer:
    2,385
    Location:
    North of Sydney.
    Don't forget a dished 36 mm ring spanner to go with the puller.
    EBC do a clutch holding tool for $20 (eBay)
    2nd drive gear needs to be removed to get to 3rd but am going to go the hydraulic press route.

    http://s30.photobucket.com/albums/c345/manurewa/DR%20General/DRgear/

    Ideally you need the con rod locking tool also.
    I had no problem splitting the cases without the case tool personally.
    #21
  2. rch10007

    rch10007 Dotted Quad Ranger

    Joined:
    Aug 18, 2010
    Oddometer:
    39
    Location:
    Clarksville, TN
    I have the following:

    clutch holding tool - motion pro
    conrod tool - oem suzuki (ebay from Israel)
    blind bearing puller
    36mm wrench from northern freight
    case separator
    socket for the crankshaft...(forgot the technical name)
    gear puller

    I think that's all the "special" tools I used. I'm sure other folks may find them unnecessary but I can tell you that having the right tool makes things so easy and you're less likely to screw something else up...

    I got my DR for a screaming deal so I used that as an excuse to purchase more tools... When it's all said and done, I will have a fresh motor with all new bearings (which I ordered Friday) and still have less in the bike, with these new tools, than you can buy a comparable DR for.

    I hope you have good luck finding the tools. I am in no hurry so I set up alerts on ebay and craigslist to tell me when someone posted one of the tools for cheap... When they did, I bought them.
    #22
  3. ADV8

    ADV8 Taumarunui..Darwin..

    Joined:
    Nov 10, 2007
    Oddometer:
    2,385
    Location:
    North of Sydney.
    I got that tool from the exact same eBayer.

    shira1171

    fwiw for folk who are looking still.
    The EBC clutch tools are made to suit each bike model.

    worldwide_motorcycle_equipment

    [​IMG]
    #23
  4. rocksterboxer

    rocksterboxer n00b

    Joined:
    Apr 4, 2009
    Oddometer:
    9
    Finally took the top end off. This is what I found:
    [​IMG][​IMG]

    The cylinder lwas spared but so far con rod and piston are not looking good. Waiting for puller and splitter to know more. What a bitch to get the cam sprocket and chain off with a seized engine.
    #24
  5. Rhyno

    Rhyno PrsnalityAccentuator

    Joined:
    Oct 29, 2012
    Oddometer:
    87
    Location:
    1000 Miles from nowhere.....
    I have read through and I am curious as to how its coming or how it's running....

    Any updates?

    Thanks.....
    -Rhyno
    #25
  6. rch10007

    rch10007 Dotted Quad Ranger

    Joined:
    Aug 18, 2010
    Oddometer:
    39
    Location:
    Clarksville, TN
    Got it back together, rode the shit out of it for a few thousand miles and sold it for another project... The motors are reliable as hell if someone puts them together the right way. :D
    #26
  7. Rhyno

    Rhyno PrsnalityAccentuator

    Joined:
    Oct 29, 2012
    Oddometer:
    87
    Location:
    1000 Miles from nowhere.....
    Thanks for getting back to my question.....

    Are there any lessons learned? Maybe something that you would've done different? Parts or Parts Suppliers?....Machining and Balancing?....

    Thanks.....Rhyno
    #27
  8. rch10007

    rch10007 Dotted Quad Ranger

    Joined:
    Aug 18, 2010
    Oddometer:
    39
    Location:
    Clarksville, TN
    A few things I learned, or was told. Not saying this shit is true, just what I was told:

    Never put bearings in a freezer.
    I used an old space heater and laid the cases on top (bearings facing down) and let them warm up until the bearings just fell out. Easiest way ever to remove the bearings.
    Same for putting the bearings back in...warm up the cases and the bearings drop right in.
    Clean and organize EVERYTHING before even thinking about starting the rebuild. If you have everyf*n thing lined up according to the manual BEFORE assembly, it goes like a hot knife thru butta!
    Get a manual--or print one out...
    A helping hand helps.
    After completed assembly of the entire bike, take the rest of the day and don't come back to it until the following day and recheck everything. Then, start your break in process.
    I started the motor, let it idle high for about 2 mins, then shut off and let completely cool. Then 5mins, then 10 mins, then 20mins. After cooling from the 20min run, I suited up and rode that bitch like I stole it. After a couple of hours of flogging, I changed the oil, checked everything again and let her rest. Next day, check everything for any leaks or whatever is out of the ordinary and then run a compression test. All was perfect, so another test ride and come home, washed her up and put her in her place.

    [/story] :freaky
    #28
  9. Rhyno

    Rhyno PrsnalityAccentuator

    Joined:
    Oct 29, 2012
    Oddometer:
    87
    Location:
    1000 Miles from nowhere.....
    Thanks......
    #29