Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Suzuki DR & DRZ => Topic started by: Matie spero on July 26, 2017, 05:06:25 pm

Title: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 26, 2017, 05:06:25 pm
Ok

So I started with a spotless DR, 2009 model with 11 000 km on the clock.
Bought it second hand from a member on the forum 5 years ago, saw, tested and paid (going to ABSA, taking out a loan) within 4 hours.

a lot has happened since then, however the lust/love for her is as strong as the first time I saw her.

So with my shit being all over the place, and me living under the illusion that everybody reads/enjoys the shit I type, I thought ill make a dedicated thread to consolidate stuff.


Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Gérrard on July 26, 2017, 07:04:22 pm
:thumleft: Mine's older brother from another mother.
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 27, 2017, 11:47:46 am
Mods on the bike:
  Front suspension:
       Eibach Straight Rate .55 Fork Springs   
       Ricor Racing Intiminator Inertia Valves   

  Rear suspension:
      Eibach Shock spring 8.3 kg/mm   

  Carburation:   Link to all the info you will ever need on the BST 40 carb: http://www.wilddog.za.net/forum/index.php?topic=172129.0
      Drilled an extra hole in the slide. (quicker response)
      Shortened the slide spring by 2,5 turns (quicker response)
      Pilot jet from 42.5 to 45
      Main jet from 140 to 152.5
      Self tapered needle
      D-shelf mod (grinded off the plastic spacer on the one side)
      Extended fuel mixture screw

  Airbox:
     TwinAir Air Filter   
     Snorkel removed
     50mm hole drilled (more air) 
 
  Exhaust:
    FMF Q4 Slip-On (spark arrester removed)
    Ground down the weld in the header pipe

  Side stand switch removed

Farkles:
    Supermoto Front Fender   
    Aluminum Bash Plate “Lecap”   
    Lowered & wider footpegs
    Steel Braided Brake Line - Front and back   
    Screens for Bikes tinted screen (removed, playing around with other ideas)
    CYCRA hand guards   
    Fly Aero Pro-taper Handlebar kit   
    Handlebar Raisers   
    Mirror Extenders 2 inch   
    12v “lighter” port 
    FMF pipe converted to tool tube   
    Custom made “Groenie” Pannier Rack (Fits Dirtbagz)   
    Custom made “Groenie” Rack   
    Tidied tail light
    LED license plate light
    Small licence plate

Wish list:
    Acerbis long range tank
    LED spot lights



Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on July 27, 2017, 03:46:29 pm
Nearly as fast as my blue one! :biggrin: :biggrin:
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: DeepBass9 on July 27, 2017, 04:09:00 pm
Wish list:
    Acerbis long range tank

http://www.wilddog.za.net/forum/index.php?topic=212377.new#new
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 28, 2017, 10:29:40 am
Nearly as fast as my blue one! :biggrin: :biggrin:

That's only because I tapered your needle better than I did my own!!!!!
You're welcome!

 :pot:
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 28, 2017, 01:55:54 pm
So where did it all the repair and tuning start?

Feb 2015, a couple of us went to Swazi for a weekend of riding.
First day going up a erosion rut on a hill, I managed to clip a rock that was concealed in some bushes.
This resulted in my oil filter cover smashed.

a lekke bush mechanic and some major luck, ended up riding the next day.

Ride report: http://www.wilddog.za.net/forum/index.php?topic=169594.msg3178838#msg3178838

Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 28, 2017, 02:19:27 pm
So back in SA JUST A NEW OIL FILTER COVER was the plan!!!!
There was more than enough thread left the bolt the cover on.

Me being a popper a *anally retentive nut case this would never have been a viable solution.

Next in line options:
   1) Get a quote from Suzuki the get a new clutch cover.
       Chocked a little when I received the quote and got asked to leave the shop after my response: "dammm I usually get a dinner and a couple of glasses of decent wine before someone tries to f#@k me like this!"

   2) Get my casing welded up and retapped.
       Cost involved was also really not cheap, repainting & colour matching bla bla bla (being retentive again)

   3) Started trawling the internet for a second hand casing.
       That's where I got in contact with Chopper Pilot, and bought a casing from him that's more or else in the same condition as mine.
       



* The term anal retentive (also anally retentive), commonly abbreviated to anal, is used to describe a person who pays such attention to detail that it becomes an obsession and may be an annoyance to others, potentially to the detriment of the anal-retentive person. The term derives from Freudian psychoanalysis.
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: 0012 on July 28, 2017, 02:48:34 pm
 :sip:
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 28, 2017, 03:07:28 pm
A strip to JUST REPLACE THE CLUTCH CASING could never be just as simple as that...

a Retentive cleaning a polishing project followed, and a carb clean was top of this list.

Why cant I just clean a carb and be done with it? well I knew I was not running optimally since I was back firing quite heavily on deceleration.

Short and sweet of it:
  Ended up doing a theses level research project on the stoichiometric combustion of fuel.
  Followed by a PHD level research project on carburettors  (especially the Mekuni BST 40)
  Finally ended up with a needle taper of my own, which I believe results in a combustion within the stoichiometric band.

Also grinded down the weld on the header pipe.

Full report on that expedition: http://www.wilddog.za.net/forum/index.php?topic=172129.0
 
Title: Re: 2008 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 28, 2017, 03:56:16 pm
Almost a year later she was polished re assembled with a few extras:

New screen, attached with Velcro for easy removal (lots of you tube video's on this)
GPS cradle
RM 250 sticker kit I butchered
Pimped carb
Second hand clutch casing
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 31, 2017, 02:45:14 pm
Unfortunately after al of the above spanner swinging/ polishing and tender love and care, she started smoking.
Like a real rebellious child!!!!!!

Took her for a couple of outings, where I tried to punish the smoking out of her, but alas, like any stubborn child this only made it worse.

hahaha even had to tow Kykdaar back home after our ide out to Oggies!!!!
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 31, 2017, 02:48:54 pm
Some more fun:
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 31, 2017, 02:57:07 pm
I must admit the power after the needle tapering was insane,she really was a different beast!

However as I don't like too much speed I dropped a tooth on the front sprocket, best decision ever!

Now she is nippy, and can still highway cruse 140-150 km/h with ease.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 31, 2017, 03:12:20 pm
So about a year ago, after a ride I heard a noise that lead me to think her wheel bearings needs to be replaced.

New bearings and seals all-round!!!! yeaay  :pot: :pot: :pot:

Also try and do something about that smiley I gave the front wheel on my last trip.

As I took the bearings out, my eye catches this little funny crack just behind the smiley...

So that was the sound I was hearing, not the wheel bearings, the smiley is about 5 cm from where the wheel was joined, and that resulted tare in the joint.

so that's where I parked her, smoking and cracked rim. haven't started her since.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 31, 2017, 04:00:31 pm
To do list:

The smoking:
Had it that it was the valve stem seals, they could have been damaged when I klapped the rock in Swazi.

Front wheel:
Well here's where my good friend Chopperpilot once again came to me rescue, however a gentle man never kisses and tells.....

Repack the exhaust
It ahs been 20K km.

I sent the head so basil's engineering, to have the seals replaced, where I got some not so lekker news:

All in all the smoking was not due to the head!!!!!!!!!!![/list]
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Herklaas on July 31, 2017, 04:07:58 pm
 :sip: Very naais, but, jislaaik Broer, you could have bought a secondhand Ferrari with the money you threw at that bike.  :spitcoffee:
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on July 31, 2017, 04:08:56 pm
Repacked the exhaust sat, what a KAAAAAARK job!

There's fibre glass every where!

Never going to do that again!!!!!!!!!!!!!
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 02, 2017, 07:24:07 pm
Regarding the smoking...are the rings ok?


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Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 17, 2017, 10:42:34 am
Regarding the smoking...are the rings ok?


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So apparently these 4 strokes does not like to stand for long periods of time.
Spoke to some of my oracles, and they all seem to be in accordance that my oil ring might have collapsed.

New rings and base gasket ordered, should be getting them tomorrow.

so what started out as just replacing the valve stem seals, now seems to be an entire top end rebuild....

Will check the barrel and maybe get it honed, but I doubt that I will do that.......

Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 17, 2017, 11:04:37 am
Gaan jy dalk nie "hone" met nuwe ringe nie? :o
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 17, 2017, 11:13:32 am
Gaan jy dalk nie "hone" met nuwe ringe nie? :o

Ek het daai barrel so gekyk (nog nie af gehaal nie), en ek kon nie eers n merkie sien nie.

Ek sal mooi kyk sodra ek die cylinder af gehaal het, maar ek glo nie dat dit nodig sal wees nie.

Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 17, 2017, 11:24:26 am
Jy moet mos "hone".

Gaan mos nie oor skade nie, maar sodat ringe kan "seat". Cylinder moet "grof" wees.

Ek twyfel, maar ek mag verkeerd wees.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: ChrisL - DUSTRIDERS on August 17, 2017, 11:44:49 am
 maybe get it honed,

Ek sal dit doen. :deal:
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Tony the Boney on August 17, 2017, 12:33:21 pm
 :sip:
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 30, 2017, 01:39:36 pm
Since the last post I went on holiday, lekker Struisbaai, got new rings and base gasket and a new second hand front wheel.

Took the cylinder off.

The barrel seems more than fine.
The chafe marks are not even as deep as the honing marks. Good sign.

The oil ring did not seem collapsed or damaged at all.
The openings in the rings are spaced correctly.

So where the oil came from I do not know, there's only 3 possibilities:
1) Head - checked and valve stem seals replaced
2) Rings - fitting new ones
3) Gaskets - fitting new ones

Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 30, 2017, 01:42:26 pm
I also cleaned the head and piston
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 30, 2017, 02:14:05 pm
Goeie werk! Laat weet sodra sy weer loop.


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Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 30, 2017, 02:16:24 pm
Goeie werk! Laat weet sodra sy weer loop.


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Chopper

Sy loop nie, sy hardloop.... :ricky: :ricky: :ricky:

as sy vlerkies gehaad het, het sy gevlieg
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Piet on August 30, 2017, 02:46:16 pm
Since the last post I went on holiday, lekker Struisbaai, got new rings and base gasket and a new second hand front wheel.

Took the cylinder off.

The barrel seems more than fine.
The chafe marks are not even as deep as the honing marks. Good sign.

The oil ring did not seem collapsed or damaged at all.
The openings in the rings are spaced correctly.

So where the oil came from I do not know, there's only 3 possibilities:
1) Head - checked and valve stem seals replaced
2) Rings - fitting new ones
3) Gaskets - fitting new ones
Two questions:

What's with the chip-outs on the bottom end of your piston? It looks like pieces of metal broke out there brittly. Or is that how they are manufactured?

Are there good reasons against reducing the weight of the piston by grinding away some of the excess material?  :pot: Compare KLR 685 piston to stock piston:
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 09:27:25 am
Two questions:

What's with the chip-outs on the bottom end of your piston? It looks like pieces of metal broke out there brittly. Or is that how they are manufactured?

Are there good reasons against reducing the weight of the piston by grinding away some of the excess material?  :pot: Compare KLR 685 piston to stock piston:

Hi Piet,

Yes manufactures like that.

I have it as to give clearance for valve opening, so there is no interference.

I now see what you are referring to, no its manufactured like that. probably to let oil pass easily.

I have never thought of the idea to take metal of a piston to reduce weight myself!
The risks with regard to piston failure as result of compromised structural integrity is just too high.

High performance/higher compression pistons that are the way to go...
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: sidetrack on August 31, 2017, 09:49:01 am
Daar was baie carbon op jou piston gewees ?
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 10:09:02 am
Daar was baie carbon op jou piston gewees ?

Jip, syt lekker gerook op startup, kon nie veel agterkom as ek ry nie, maar dan weer ek kyk nie veel agtertoe nie en Kykdaar is altyd sover agter hy kon ook nie sien nie!

 :imaposer: :imaposer: :imaposer: :ricky: :ricky:
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 01:22:32 pm
All in a nights work:

Cleaned the cylinder
Cleaned the rocker cover
Installed new rings
Installed the cylinder and base gasket
Installed the head and head gasket
Installed the cam

Nothing torqued yet, I am in dispute with the manual (more on that later).

Fitted the fuel tap
New wheel bearings and dust seal for the front wheel.

En so bietjie foggies net om als mooi gelube to hou...
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 31, 2017, 01:30:24 pm
Gelukkig nog 'n halwe bottel oor vir vanaand! :o

Wat pla van die manual? ???
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 01:33:15 pm
When I removed the head bolts I placed them, in the sequence I took them out, on the floor.

The manual has a different sequence, I have it that B and C should swop around...
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 31, 2017, 01:38:20 pm
Is dit die tappet cover boute waarvan sommiges die brass washer vir die oliekanaal het?

As jy die boute laat sak, voor jy hulle indraai, meet die afstand tussen die boutkop en cylinder head. Dalk word jy iets wys?
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 01:40:17 pm
Is dit die tappet cover boute waarvan sommiges die brass washer vir die oliekanaal het?

As jy die boute laat sak, voor jy hulle indraai, meet die afstand tussen die boutkop en cylinder head. Dalk word jy iets wys?

Nee dis die lang head bolts wat onder in die casings vas trek.

Het hulle in my volgorde in gesit en almal was ewe hoog van die head af
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 31, 2017, 01:48:28 pm
Bevestig dat 2 van die head bolts, wat buite die tappet cover is, die brass washers op het?

Het jy die washers verwyder, of is hul nog daar?

Kan dalk 'n fout in die manual wees?

My logika se vir my om die afstand tussen bout kop en cylinder head te meet, soos wat jy reeds gedoen het.

Indien jy die twee gaan omruil, soos per manual, sal daar 'n groot verskil in die kop tot cylinderhead afstand wees, wat nie korrek is nie.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 01:48:40 pm
When I removed the head bolts I placed them, in the sequence I took them out, on the floor.

The manual has a different sequence, I have it that B and C should swop around...

OK so ek is reg en die Manual is verkeerd!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

OEM parts list ek op internet kry het dit soos ek dit het.
Die twee 180mm boude kom links (ander kant van cam chain) en nie voor soos die manual se nie.

Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 31, 2017, 01:50:43 pm
Jip! Wou ook 'n ander bron voorstel!

Het jy nuwe brass washers?
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 01:51:25 pm
Bevestig dat 2 van die head bolts, wat buite die tappet cover is, die brass washers op het?

Ja hulle twee het die brasss washers in my foto op.

Die ander twee het ook brass washers op is net af in die foto.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 01:53:11 pm
Jip! Wou ook 'n ander bron voorstel!

Het jy nuwe brass washers?

Nee nie nuwe washers gekry nie, volgens n paar motorfiets werktuigkundiges is die nie nodig nie, as ek ooit weer hierdie moet doen sal ek hulle vervang.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 31, 2017, 01:56:34 pm
Jip! Wou ook 'n ander bron voorstel!

Het jy nuwe brass washers?

Nee nie nuwe washers gekry nie, volgens n paar motorfiets werktuigkundiges is die nie nodig nie, as ek ooit weer hierdie moet doen sal ek hulle vervang.
Bakgat! Loop sy vanaand!
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: Matie spero on August 31, 2017, 02:20:50 pm
Jip! Wou ook 'n ander bron voorstel!

Het jy nuwe brass washers?

Nee nie nuwe washers gekry nie, volgens n paar motorfiets werktuigkundiges is die nie nodig nie, as ek ooit weer hierdie moet doen sal ek hulle vervang.
Bakgat! Loop sy vanaand!

nee ekt die kids vanaand.

Dan ook n dag gee vir gasket maker en locktight om te settle, sal seker saterdag of sondag haar eerste swaai gee.
Title: Re: 2009 DR 650 SE - The repair, farkle and abuse of Deedre
Post by: chopperpilot on August 31, 2017, 04:08:46 pm
 Ek wag in spanning!


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