My DR650 Rebuild Project Thread (Yossi / Israel)

Discussion in 'Thumpers' started by jossef, Jun 30, 2009.

  1. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    Hi everyone,
    I would like to start a rebuild thread of my DR650.....as I promise to Mezo last week. since it is my first time here let me introduce myself....My name is Yossi and I am from Israel, age 40 married with 3 kids,my love to suzuki thumpers started 20 years ago and since then the DR650 is my favorite bike. I read a lot on ADV but always stays in the background.....
    So, the story of this rebuid begun last year while buying a faulty motor, year 99 from a friend who decided not to fix it, so I bought it and started an overhall. The engine was disassembled in order to find the root cause of the noise been generated while changing gear.

    [​IMG]

    I started by taking off the clutch cover and the problem immidiatly appear, the primary gear axe was moving, and the bearing had significant play. I then understand that I need to open the case in order to replace this particular bearing......


    [​IMG]

    So the goal of the project are:
    1- rebuild the engine: replacing all bearings, all oil retainers, gaskets, rings, piston etc'
    2- Then find a bike with a broken engine, pay cheap and install this one.
    3- Rebuild the whole bike from scratch so at least it will be like a new one.
    3- Build a bike which will be a real adventure bike, good both for off and on road.
    4- comfortable.
    5- Able to ride long distance with larger fuel tank.
    6- and then if I don't have budget problems , start upgrading each module like: shock absorber, brakes and accessories.

    Realy don't know how this bike will look at the end .......with these kind of projects you know how you start but don't know how it ends, so I will go slowly slowly step by step.....

    So I start with the head removal, camshaft etc

    [​IMG]


    and the cylinder. As you can see the walls were shiny. Before assembling back, I tried the scratching stuff with scotch-bright and WD40 as recommended in many websites for Nikasil material- what I can tell you guys this is BS- Nikasil is very hard no scotchbright can do anything to it unless I missed something here.....

    [​IMG]


    while inspecting the clutch cover I noticed that a piece of metal is missing arround the clutch rod (in the middle of the picture)- I assume this was the root cause for the demaged bearing of the primary gear axe. Probably the rod had some play and clutch release was not smooth as should be.

    [​IMG]

    To make the long story short the case was openned and finally reached the faulty bearing and removed it....

    [​IMG]

    On the way a new set of engine bearings was bought and the old ones got replaced.

    [​IMG]

    so as all the oil retainers...

    [​IMG]

    Then after the case was closed I install a new JE piston+rings, this is a high comp one 10.5:1 instead of 9.5:1.
    Here I want some feedbacks from you guys regarding this uograde. How does the engine feels ? how is the riding with the new piston?

    [​IMG]

    keep moving upward...now it was the engine head turn to be rebuilded. all valves spings and stuff were dismantled and kept in separate boxes.
    Head was cleaned thoroughly and start lapping the valves seats.

    [​IMG]



    Nice to meet you all.....welcome to my shop.


    [​IMG]

    Once the head was ready I put the valves and springs back to their original places.....now it was the valves cover assembly to be taken apart: all shafts were inspected and measured with a micrometer to make sure they are in spec limits, then moly pasted them and lube.

    [​IMG]

    Don't get me wrong....This pix above is the "before" cleaning....
    #1
  2. LukasM

    LukasM Long timer

    Joined:
    Nov 15, 2006
    Oddometer:
    5,445
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    On a RTW ride - next stop USA!
    Jossef,

    I got a sneak peak at your project from Mezo and thought it was great. Looking forward to seeing more of it! :clap

    Lukas
    #2
  3. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    Hi Lukas
    thanks, I will try to write a little each time to keep you updated, since I have a lot of pictures/photos
    You can call me Yossi.
    #3
  4. clinton1396

    clinton1396 Adventurer

    Joined:
    Jun 14, 2009
    Oddometer:
    10
    Location:
    York, Pa
    I just had to crack my crankcase open on my sp200 same as dr just to replace this drive shaft part b/c a bolt snapped off into it that made me mad lol. but it was a great learning experience good luck with the project
    #4
  5. NOSIGN

    NOSIGN Adventurer

    Joined:
    Apr 12, 2009
    Oddometer:
    94
    Location:
    Melbourne, VIc
    Hi Yossi,

    looking with interest...
    #5
  6. nave

    nave Nave

    Joined:
    Apr 5, 2006
    Oddometer:
    354
    Location:
    Israel
    Hey Yoosi,

    Come on, don't be lazy and load more pix...
    :clap
    Nave
    #6
  7. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    have plenty of photos....have hard time to upload them since they are high quality and this takes time....
    I will do my best.
    Yoss

    #7
  8. Mezo

    Mezo Banned

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    Nov 17, 2008
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    Brisbane,Australia.
    Hi Yoss, superb mate, thanks for taking the time to post & write up the build, you will inspire others to "have a go" :evil

    Yossi had read my build thread & Lukas`s, he had mailed me some pics of his bike i forwarded them to all the other DR builders on the forum, and all agreed Yossi has talent & they told me to "convince him" to post his build, and voila :thumb

    macdesign oops, there i go it just blurted out, macdesign is also building a very trick DR650, im trying to "convince him" also to post a thread :D see married men with children can find time to play with there toys.

    Ive put a link to your build on my own site, i must get round to that other project of mine The DR650 Builders WALL-O-FAME

    Cant wait for the next installment Yoss, there will be plenty of popcorn munchers on this thread :D

    Me for one, :lurk

    Mezo.
    #8
  9. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    shall be "rebuild" instead of "rebuid" ?
    #9
  10. Mezo

    Mezo Banned

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    Brisbane,Australia.
    Pres "edit" on your post & then press "advance edit" at the bottom :evil

    We knew what you meant mate.

    Mezo.
    #10
  11. kuyaoli

    kuyaoli Been here awhile

    Joined:
    Dec 8, 2008
    Oddometer:
    320
    Location:
    Bangkok, Thailand
    ask one of the mods to change it for you the title can not be edited by yourself.

    By the way, great start, I am looking forward to see more of your rebuild.
    #11
  12. DisTech

    DisTech Been here awhile

    Joined:
    Sep 3, 2008
    Oddometer:
    616
    Location:
    Seattle
    I've seen the preview's (thanks Mezo) and I'm really glad your decided to do a build thread. Good luck and keep it coming! :lurk
    #12
  13. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    Thanks Mark
    What happens with the thread at the end- does someone moves it to the main "DR650 Thread"? or can we move it now? so it can be tracked...you get lost after with all the information.....

    Yossi

    #13
  14. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    "Before assembling back, I tried the scratching stuff with scotch-bright and WD40 as recommended in many websites for Nikasil material- what I can tell you guys this is BS- Nikasil is very hard no scotchbright can do anything to it unless I am missing something here.....

    JE HC piston how does it impact power ? any feedbacks on this upgrade?

    Thanks
    Yossi
    #14
  15. DRjoe

    DRjoe Long timer

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    Sunshine coast qld
    Good to see you started a report on your build.Like mezo said it will inspire others.

    It's looking good so far.

    Joe
    #15
  16. kano650

    kano650 more cowbell

    Joined:
    Oct 1, 2007
    Oddometer:
    217
    Location:
    Adelaide - nth east side
    cool another DR rebuild thread
    :lurk
    #16
  17. jossef

    jossef Adventurer

    Joined:
    Mar 26, 2009
    Oddometer:
    37
    Tried to correct the tiltle with no success "who is one of the mods"?
    Help
    Yossi


    #17
  18. Mezo

    Mezo Banned

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    If you go to the thumpers index top of your page (just click on the word thumper Yoss) then page down to the bottom of the main thumper index & you will see the moderators of this forum (gadgetboy & gaspipe) click on the name & you can then ask them to fix your title.

    Mezo. :thumb
    #18
  19. GB

    GB . Administrator

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    Fixed your thread title as per your request.
    #19
  20. Kawidad

    Kawidad Long timer

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    Central Coast, Cal
    :nod:thumb
    #20