the DR650 thread

Discussion in 'Thumpers' started by sleepywombat, May 1, 2006.

  1. ADV8

    ADV8 Taumarunui..Darwin..

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    2,385
    Location:
    North of Sydney.
    We got flown out at short notice this afternoon from the gas project back to Darwin (A week early) with a cyclone warning.
    There were lots of packages that have arrived over the last two weeks including two from Jeff. :evil

    Jeff is a legend,i was going to order some rotor bolts on Monday,no need he threw a set in . :thumb

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  2. Mezo

    Mezo Banned

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    I saw that report on the local news Les (cyclone) so they pulled you guys off the rigs, that`s a bonus you still get paid right? there will be hundreds flying back to Perth & straight to the garage to fire up the bikes, mind you were at 40 tommorow, 37 today, to hot for riding.

    Nice to see you back Les.

    Mezo. :thumb
  3. kuyaoli

    kuyaoli Been here awhile

    Joined:
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    Nairobi, Kenya
    I guess I am invisible...:wink:
  4. Mezo

    Mezo Banned

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    Ya know id missed this post, was it because it was in KTM orange i wonder?

    Just wait for Jeff to chime in. :evil

    Your only slightly invisible :D

    Mezo.
  5. Birdmove

    Birdmove Long timer

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    Location:
    Keaau, Hawaii
    Any known weaknesses to the new DR650s? I've heard that an earlier model year had some kind of starter problems, and up until a few years back there was a problem with the cylinder base gaskets (now updated). Seems like a very solid motorcycle. The KLR650 shave their "doohickey". DRZ400s seem to have a problem with the automatic cam chain adjusters. Honda XR650Ls-some have a problem wearing out their countershafts way too early.

    Jon
  6. thumpididump

    thumpididump MacGyver

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    http://dr650.wikia.com/wiki/Potential_problems_to_be_aware_of


  7. ditchbanker

    ditchbanker Owner of dull user line

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    A big part of the reason I choose the DR over the KLR was that its issues were a matter of slow improvement, where the KLR, from where I was looking, needed improvement instantly. I was a poor college student when I bought mine several years ago, so these were concerns to me. To protect the KLR, I needed to get nerf bars instead of just a skid plate. The breaks sucked, which was something I felt would need immediate attention. The doohicky was a concern.

    The DR primarily had comfort items. Seat. Bigger tank (may be necessary depending on location, I got along fine for a year with my stocker.) Mine came with a rack, so it wasn't a concern. The starter makes funny sounds on mine when cold, but still works just fine. The base gasket started leaking when I switched to semi synthetic oil. Despite the puddles I'm leaving, I'm not dropping enough to really see effects on my fill level between changes. I'm fixing it this winter. All of these deficits were things that could be fixed at my leisure, rather than spending dough on a brand new bike. That was a big consideration for me.

    Also, don't forget weak sub frame on XRL.
  8. procycle

    procycle Long timer

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    Hey Oliver,
    The carb swap can be done without even looking at the installation notes. You have had the stock carb out of the bike for jetting right? Just remove the stock carb and cables and replace them with the new pieces.

    I haven't seen anyone make a step by step installation pictorial. That is on my wish list for things to add to our web site.

    There is one step that may not translate easily. On the rubber mount that holds the carb to the engine there are a couple of rubber tabs that locate the carb so it can't be installed at an angle. Those tabs will prevent the TM40 from seating fully into the rubber mount. You have to cut them off flat with a razor blade or sharp knife.

    If you have specific questions about the carb installation feel free to email me directly through the www.procycle.us web site.
  9. smilin jack

    smilin jack Grandpa Adventurer

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    Location:
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    Made a wooden chainsaw bar cover from 3/4" plywood yesterday.

    It took two pieces about 6" wide by 28" long. The length is determined by the chainsaw bar length. The two pieces are spaced apart by narrow strips of 1/2" plywood, glued and screwed together to make a bar cover.

    This bar cover has holes drilled along one long edge to match the steel mount that was made in August. Removed the Kolpin rifle case and bolted the saw bar cover onto the bike.

    The chainsaw bar is inserted into the wood sleeve, a bungie is attached to the saw to keep from bouncing out, and ready to hit the hills to open up trails and roads of wind fallen trees.

    Here is a picture of the steel accessory rail attachment. Will post pictures when the wood gets painted.

    Notice the melted plastic from the previous owner having saddle bags. I made the aluminum heat shields from an old patio door track, and bolted on using existing bolts. Same with the accessory rail.

    Dave
  10. smilin jack

    smilin jack Grandpa Adventurer

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    OK, here's the picture of the saw on the bike.

    Got the bar cover varnished today and mounted on the bike. The plywood was salvaged and don't know what the burn marks are from but used anyway.

    The accessory bar mounts on the turn signal tapped hole and the passenger foot peg bolts, so can return the bike to stock configuration quickly.

    Hope to go riding soon and try out some wind-fallen tree blocked trails.

    Dave

    Attached Files:

  11. smilin jack

    smilin jack Grandpa Adventurer

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    Here's the Kolpin rifle case bolted on the accessory bar.

    Dave

    Attached Files:

  12. Paloma Paul

    Paloma Paul Paloma At Its Best

    Joined:
    Feb 19, 2007
    Oddometer:
    385
    Location:
    Paloma Arizona
    I just finished installing a 270 Kenda on the rear. Boy was it a sob to get the bead to seat!!!! Any suggestions for next time on an easier way to seat a bead? AlsoI usually run 24-28 psi for tire pressure on black top, 15 in the dirt with 2 rim locks any suggestions thanxs
  13. kuyaoli

    kuyaoli Been here awhile

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    Thanks Jeff, I guess I just have to start doing it and see what will happen. Good to know that I have to look for some rubber tabs to cut off.

    If I encounter a problem I will let you know.
  14. ADV8

    ADV8 Taumarunui..Darwin..

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    I had a step by step install but must have deleted the folder in my netbook thinking it would never be used.

    Here is a basic picture taken a few minutes ago.
    You trim the two rubber lugs in this area to make the face flat so the carb sits flush,they normally hold the clamp in place.

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    The only other thing i did was cut off the other idle adjuster since it is not needed.???
    It may be an isolated case but it was to close to the frame for my liking but i have no problem chopping even new TM40's :D
    Just mentioning it not saying it has to be done,might be a one off in my case.

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    Another reminder to keep an eye on the cheesey sidestand pivot.
    My swingarm has a gouge in it now when it started rubbing on the last trip,my DR will be two years old in January and the pivot even lubed was starting to wear fairly quickly.
    This didn't work that well,the swingarm angle flattens when riding the bike and the foot can still rub.


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  15. thumpididump

    thumpididump MacGyver

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    I'm planning to get a TM40 carb this winter, to purchase from either Kientech or ProCycle. Does anyone know if there is any difference between the kits they sell? There is a $75 difference in the price and I suspect there's a reason.
  16. kuyaoli

    kuyaoli Been here awhile

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    Les, thanks a lot for your pictures and explanation. I just hope that aside from this rubber tabs I don't have to cut off something. :evil

    Did you just lead down all the vent hoses infront of the swingarm? I may have to do that also with the one coming out of my original Californian tank.

    How long does the installation of the TM 40 take, if you do it the first time and very slowly? About 1 hour, 2 hours ?
  17. NordieBoy

    NordieBoy Armature speller

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    The Procycle one have machined adapters for the manifold/airboot ends.
  18. thumpididump

    thumpididump MacGyver

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    Ah. thanks. ...but how exactly does Kientech's carb fit then?

  19. procycle

    procycle Long timer

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    Loose! :huh

    Actually Jesse includes stronger hose clamps to squeeze the rubber boots down onto the carb. In my view this will only work for a while. Eventually the intake boot will crack from being squeezed down to fit the smaller sized carb spigot. I've seen this happen on plenty of other bikes and didn't want folks to have problems with vacuum leaks 2-3 years down the road. The adapters actually make for a somewhat tighter fit and use the stock clamps.
  20. procycle

    procycle Long timer

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    Yeah, the extra idle screw tab is not needed and does come pretty close to the frame. No harm done by slicing it off.