Pre '96 Suzuki DR650S

Discussion in 'Thumpers' started by DRS Canada, Dec 5, 2004.

  1. Trust

    Trust I'll fix that

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    Impact gun is how I got it off. Zap that thing so hard/fast with the gun it doesn't have time to think about moving. You can also improvise a tool - I've done that in the past but the gun was faster. If your springs are out of spec I presume the clutch would slip.
  2. puntoMX

    puntoMX Lost in Cyberspace

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    Got to buy one of those for my next birthday for sure :evil , but for now I can't but I'll see about just doing it with the tools I have. Why didn't they make it so you just pop in a screwdriver in some hole to lock up the clutch... Any way, if it's not the springs or the plates, I wonder what could be it than... I'll drive it a bit more until I can hear better what and how (until it REALLY makes too much noise). :rofl

    I didn't reply on your mail as I didn't had time enough to sit down today... will do soon! :D
  3. 685

    685 Scarred Adventurer

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    nope, you can't. It takes some sort of impact tool to get the nut off. I used the 'hit it with a hammer' style impact driver--which is a lot less expensive than an air or electric impact.

    Sorry
  4. puntoMX

    puntoMX Lost in Cyberspace

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    My new exhaust came in today, also the rear light, hand-guards, 3 tirespoons and those are
    indeed the KTM ones, cheap used GPS and some small stuff. :D Pictures coming up from the
    rear-light when the batteries are charged from my camera and we'll see how that muffler will be
    fitted. :evil I'll leave the clutch for what it is now...

    EDIT: Some pictures...
    [​IMG]

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    [​IMG]

    I used a piece of tiretube to cover up the holes and silicon to hold it in place.
    The lightbulbs are not that bright but will be replaced soon by some LEDs.
  5. puntoMX

    puntoMX Lost in Cyberspace

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  6. cmdrca

    cmdrca 92 DR 650

    Joined:
    Oct 29, 2009
    Oddometer:
    9
    Location:
    Dallas, TX
    Hey Fellas,
    I've been looking here and on other sites, and can't find any specifics on a possible project.
    I have a 92 DR, which I love but is getting some issues, and I have access to a cheap, low mileage 2003 DR650 engine. I'd love to make the engine swap (and get a magic button) but am looking at what mods I'd have to make. I know I'll have to do some research to match up some wiring, but I'm most concerned about sprockets aligning, engine mounts, and engine dimensions. Any experiences with this?
  7. puntoMX

    puntoMX Lost in Cyberspace

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    Engine mounts will be the only thing you would have to make and play a bit with the exhaust. You would also need the electronics that come with the 2003 engine. I would do the wiring from scratch.

    Why not buy the 2003 engine and resell it, sell your 1992 too and use the collected cash for something else. You must have been thinking of something else, another bike; you would not just swap an engine for just a magic button I presume. :D
  8. MattZig

    MattZig Adventurer

    Joined:
    Apr 3, 2009
    Oddometer:
    26
    Just a big FYI. If anyone has a DR650 that runs really crappy, as in barely gets to 120 KPH WOT and struggles up any kind of incline.. Check your CDI. I finally narrowed it down to the CDI on my 93. Sprayed some upside down canned air to freeze it a bit and it picked up waaay more power.

    Speaking of which, does anyone have a used good one near BC, Canada? email me at matt_bred@hotmail if you do, otherwise I have to buy a new one and they're pretty pricey. Cheers!
  9. nikolic

    nikolic Been here awhile

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    Had and still having periodical problems with my CDI, but it ain't the only thing that goes wrong, take a look at your stator! Primary coil is probably shortener, and should be remade! It happens with years of riding.... My DR has more than 100k kms, and am having a lots of E problems...
  10. 685

    685 Scarred Adventurer

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    Try Ebay. http://cgi.ebay.com/ebaymotors/GENU...8700889QQptZMotorcyclesQ5fPartsQ5fAccessories I have one for a 91 (it's in Tucson, I'm in W. Washington for the next month or so.) But most of us with parts are reluctant to sell them--we're kind of in the same boat as you. Sorry I can't be more helpful.

    But also, if you buy a CDI, it may be good, but otoh, it may be failing just like your current one. Hate the price, but you may better off just taking the plunge and buying a new one.:1drink

    I'm nursing my DR along for the next month. It's my sole source of transport while I'm up here. Riding it very conservatively, these days!:eek1

    Burning/leaking oil (it gets checked every day.) And the lights dim some, like there's a loose connection in the charging system--got a good battery, and it seems to be holding a charge. Got a spare stator, too, and changing out that will be part of the overhaul process when I get back to Arizona.

    And, I'm betting that somewhere in the kick starter system, there's a missing gear tooth, 'cause sometimes when I'm kicking her to life, the k/s just lets loose.:eek1

    Fun & games!
  11. puntoMX

    puntoMX Lost in Cyberspace

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    So, after asking what that conically recessed head bolt was holding up, as it was leaking some oil there and some noise came from the head section, and no one answered... I ripped it open.

    Next time I should NOT be such a sissy :D to be scared that I will break something. So, after getting the cover off I found a nice looking inside with some minor scratches on some parts:

    [​IMG]
    Some marks on the exhaust side rocker... no idea how bad that is but 20% of the contact surface is damaged.

    [​IMG]
    The cam looks better but you can see where the rocker scratched the cam...

    [​IMG]
    On inspection of the top of teh cover I found that the surface wasn't 100% flat where the conically recessed bolt went (what a name...)

    [​IMG]
    Other view...

    [​IMG]
    Sanded it flat with 320 grid.

    Used some 315ºC silicon to close it up, also used the silicon on the gaskets of the the bolts that have a gasket. The "damage" was due to a not on spec tightened conically recessed bolt (well, that's what I thought, but it still puzzles me).

    If any one thinks I should replace that rocker please let me know and I'll look for a "new" one... somewhere.

    Just check those bolts every 6000km. :norton
  12. greendude

    greendude Long timer

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    replace the rocker arm as the rubbing surface has worn through the case hardening and will wear quickly.if you do it now you may not need to replace the cam. good luck
  13. puntoMX

    puntoMX Lost in Cyberspace

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    Shoot... so it's really bad :cry , thought it would flatten out by itself. Thanks greendude for the warning.

    I got this bike with 8.000km on it and has now just 20.000km, always used good oil and changed it on time. I did use some synthetic Yamaha oil but I don't think it would damage the rockers like that.

    What could have caused this?
    Or it's normal to change the rockers every 20.000km on a DR650?
    Could it have been to bolts not tighten up well?
    Any one having some spare rocker that would like to sell? :ear

    I'm just a bit lost on this one. :huh

    Now I think of it; both rockers show wear on the side of the distribution chain, anything ideas about that?

    Checked "syntetic oil problems" and came across this. and this. Seems also that it can block your oilfilter... :eek1
  14. 685

    685 Scarred Adventurer

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    I used synthetic in an old (engine rebuilt) Toyota Corolla--with a 12,000 mile change interval. After about 200000 miles, I tore it down, and checked. No sludge, almost no wear.

    Used the same change interval on a commercial use Ford E350 with a 5.4 l V8. Pretty much the same results.


    That said, in my motorcycles (and motorhome, too) I use regular dino oil. Motorhome, because it has seal and gasket seepage. On the bikes, there's no big advantage to using synthetic. Which ever oil one uses, the change interval is the key--don't go more than 2,000 miles. Oil in gear boxes breaks down & loses viscosity. My bike is currently using oil--needs a rebuild. So it's getting Walmart's 20w 50--which is the correct vis. for an aircooled engine.

    I don't know what damaged your rockers, could have been a bit of metallic junk in the oil that wasn't picked up in the filter. Or someone could have gone long,4,000 miles or more, on the oil change and the oil basically was worn out.

    Probably a good idea to replace them, tho. Sorry, dude!

    Those examples you posted are pretty extreme and shouldn't be taken too seriously. If you play by the rules sludge won't be a problem!:huh
  15. puntoMX

    puntoMX Lost in Cyberspace

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    I will get new ones, with a new seal (3.5USD thingy). For now I will just replace the exhaust rocker (47USD new). Really pissed me off... But, counted to 1000 and it's okay. :D

    Have to make myself the tool to replace the clutch plates and springs (complete set with metal plates, 94USD), soon I hope to get an air compressor with new toys. Exhaust has to wait a few months more till the problems are fixed with the engine.

    The engine does work smoother, but it seems that the clutch is out of balance or something attached to it, making the engine vibrate. Vibration leads to other parts transferring the noise till it comes to the front fender where the sound is louder.

    I'm using nothing else than 20w-50 too indeed, Elf Total Moto 4T.
  16. SBG

    SBG Neville1 to TT boys

    Joined:
    May 28, 2004
    Oddometer:
    359
    Location:
    Rehoboth MA
    Just cross referencing parts from the newer DR's to the older, and if anyone wanted to add some bling to their brakes, they can actually get master cylinder caps from the newer Dr's to fit the old school bikes since all the numbers are the same for almost every part. The only differences are that the new MC has a rear view mirror mount built in instead of the old style with a separate mount, and the internal piston has an updated number, but this shouldn't matter since you just want the cap.

    Look at new items under brakes: http://www.procycle.us/bikepages/dr650.html

    Gold, blue, red and silver. :evil
  17. SilverBullet

    SilverBullet Been here awhile

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    Harmaston, TX
  18. 685

    685 Scarred Adventurer

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    Well, my 91 kicked over 24,000 miles today on the way home from work. Daily ride these days and getting a work out. :clap

    Did I mention that 24901.55 miles is the actual circumference of the world. Should hit that sometime this month, I think. :norton


    Cool! (Hope it lasts that long.):lol3
  19. SBG

    SBG Neville1 to TT boys

    Joined:
    May 28, 2004
    Oddometer:
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    My 1990 only has @ 8400 miles on it. It had 6200 when I put it in storage till 2005, then went in storage around 2007 till now. Every time I get back on it, I wonder why I ever stopped riding it. I guess it's lack of local buddies who like to go dual sport riding. Some are either all dirt or all street, and honestly, all road going with cars surrounding me is boring and dangerous.

    Any pics of the 91, or have they been posted about 50 pages back?:D

    EDIT: Found it. Btw, where did you get the black seat cover? I've been thinking about getting a spare seat and black fork boots to change things up.
    [​IMG]
  20. 685

    685 Scarred Adventurer

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    Black seat was on it when I got it. Looks to be just an inexpensive reupholstery job. There's a guy on Ebay that sells nice ones, tho.

    Black fork boots were that way, too. Looks like just a matter of painting them with barbque paint.