Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Suzuki DR & DRZ => Topic started by: DeepBass9 on September 26, 2011, 05:09:59 pm

Title: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 26, 2011, 05:09:59 pm
As a result of a thread hijack, this thread came into being.....

Some history of the DR650:

http://dr650.zenseeker.net/DR650History.htm

http://www.suzukicycles.org/DR-series/DR650.shtml

http://en.wikipedia.org/wiki/Suzuki_DR650

And the service manual : http://www.visualgeobase.com/dr650/1990-1995_DR650_Service_Manual.pdf (http://www.visualgeobase.com/dr650/1990-1995_DR650_Service_Manual.pdf)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 26, 2011, 05:31:38 pm
About bloody time  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 26, 2011, 05:44:01 pm
So lets see some pics....

My '91 DR 650 Dakar... They don't build 'em like they used to....  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: punisher on September 26, 2011, 05:50:12 pm
my mate really wants one
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 26, 2011, 05:51:07 pm
Going to have to wait a month and a half for my pics, having mine transported up from east london, she will arrive on sat by that time im off to sea, but its a 95 rse exactly like the one in my profile pic, although all those plastic fairings are going!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 26, 2011, 05:52:22 pm
my mate really wants one
Pre 96 on gumtree
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 26, 2011, 06:04:15 pm
So lets see some pics....

My '91 DR 650 Dakar... They don't build 'em like they used to....  >:D

wish I could get my hands on that headlight and light fairing on your bike, going the polisport route
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 26, 2011, 06:11:16 pm
So lets see some pics....

My '91 DR 650 Dakar... They don't build 'em like they used to....  >:D

wish I could get my hands on that headlight and light fairing on your bike, going the polisport route

You can't get those plastics anymore. I have tried to get a sidecover but with no luck.

Here's a '92 on gumtree : http://capetown-westerncape.gumtree.co.za/c-Cars-Vehicles-motorcycles-motorbikes-scooters-DR-650-W0QQAdIdZ315148538
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Hondsiff Honda on September 27, 2011, 08:23:18 am
Nice! they should have run with these instead :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 27, 2011, 08:59:19 am
Here's my 94 , don't know it's history,  it has a MPH speedo. Shows 39 000 miles now.

Recently rebored to 1st O/S , new cam chain, valves recut, new stem seals and polymer plugs etc, carb emulsion tube refurbished , new parts in clutch as it was violated , and the best part, the camshaft sprocket locating pin was MISSING. The air filter was compromised and a home-made one was found in it's place.

The inside faces of the swingarm and the bushes were all rounded off due to axle movement , and the balancer chain was slack as your grannies cheeks.

Other than that, it was a solid find. I've learned to really respect this model having owned a good spread of thumpers in recent years. This bike was ahead of it's time.

Carb issues require close attention , to make it run lekker again ... I find this the biggest ailment in oldtimer thumpers. The float level being number one culprit , followed by needle wear.

This one is nearly right, but I still await new plastic carb innards from the USA to make it perfect.

(http://i971.photobucket.com/albums/ae199/Veemax/July2011rebored.jpg)



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 27, 2011, 09:04:09 am
So lets see some pics....

My '91 DR 650 Dakar... They don't build 'em like they used to....  >:D


DROOOOOLLLLL !!!!!!!!!! The Dakar is THE ONE . Damn, that's nice !!! You lucky man you !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 27, 2011, 09:07:23 am
They should reissue the Dakar, they would sell like hot cakes...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 27, 2011, 10:44:18 am
Got that right, if I had to have ONE bike , that would be it. There is not one thing or attribute you need that's not already there.  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 28, 2011, 05:14:26 pm
My bike was supposed to be picked up today but nothing yet!!!! Bad service :( :(

What did you guys do for airfilters? Struggling to get twin air filter locally, how dirt (read sand) worthy is the OEM filter?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 28, 2011, 05:32:49 pm
I'm using a new Suzuki OEM filter , treated with PJ1 filter oil well applied and massaged in. I think that's good enough. KTM uses Twinair as OEM equipment , but I fail to see any technical advantages. I don't like to sound like a wise-ass , but I've been grinding nano-particle pigments and filtering and centrifuging sub-micron particles for 10 years , there's not a lot about filtration and for that matter lazer-diffraction particle size analysis , that I have yet to learn  >:D

What I DID learn is that a K&N is crap , fine dust goes right though it an is visible settled on the intake tract !

If you are gonna ride competition or 10 meters behind the guy in front of you ... then maybe you need something fancy with very good filtration and very high dirt holding capacity ? In which case you need a 4x4 snorkel and a centrifuge pre-filter !

Nah, I reckon Suzook oil/foam maintained like you love it, is enough ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 29, 2011, 06:36:33 am
I am promised my bike back this week. Can't wait.... Now for the run in conundrum? I've read a bit about running in and everyone has a opinion, but there is no real consensus. So this is what I'm going to do: Ride the bike home nice and calm like. On the weekend I'll warm it up nicely then go on a nice long dirt ride with lots of open throttle then engine braking type of riding (maybe 300-400km) but not really pushing it too hard. Then change oil and filter and ride normally from then on.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 29, 2011, 07:19:00 am
Wheelie it out the shop and ride it like you just that second stole it for the first 50 km.

You have little time or km to seat that top ring !

This is my run-in bible and I've treated about 10 bikes this way and they've all become nice tight performers with ZERO oil usage !

The trick is to avoid low-throttle cruising at all costs , and ride like a twatwaffle  :imaposer:

http://mototuneusa.com/break_in_secrets.htm



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 29, 2011, 08:07:30 am
But I was riding like a twatwaffle when I broke it?  :laughing4:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 06:50:43 am
Right, my bikes in transit, and I'll be here to welcome her home, pics coming soon  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 30, 2011, 07:51:33 am
Wanna see wanna see wanna see wanna see  :blob7: :blob7: :blob7:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 07:59:46 am
Veemax, do you have a pic/diagram of the tank mounting brackets on the frame of the pre 96 ? I wanna put a acerbis tank on mine - see the smalls section re-acerbis tank wanted
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 30, 2011, 08:05:44 am
Not one I can click on and send right now , but if you can be patient, later today I'll have it off and will take pics for you ... I'm gonna be in there for a post-rebuild valve check ... is there something that concerns you I need to focus on? ( pun intended )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 08:09:07 am
LOL main concern being will the mounting points on the frame for the tank on the rse and the other pre-96s be the same? (the fairings are going so no prob there)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 30, 2011, 08:18:06 am
Ja I very much doubt those clever Japanese gentlemen would make a different setup for the RSE , but lets be sure neh ! Ok, so now this is the part where you wait.  I'll try to take some intelligent pics. Will put up a tape measure for reference, or a Windhoek Lager can ...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 08:19:24 am
Go with the beer can, I need an excuse to go buy a few beers..... :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DR BIG 750 on September 30, 2011, 08:40:50 am
My bike was supposed to be picked up today but nothing yet!!!! Bad service :( :(

What did you guys do for airfilters? Struggling to get twin air filter locally, how dirt (read sand) worthy is the OEM filter?
I have had my filters made locally from a place called air-tech will check out the detail & post later, i found them 1st class come with a body, filter, cleaning kit the works & real good value
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 09:21:04 am
Thanks DB, would be interesting indeed, need to replace my filter
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 30, 2011, 10:20:05 am
I'm going to fetch my bike just now........ Awesome!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Mzee on September 30, 2011, 11:34:34 am
Do they still manufacturer the DR.  Say I want a 2011, would I be able to find one?  I think it would do well for commuting.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 30, 2011, 02:34:52 pm
Of course they do, but the old ones are just waaaaaay cooler. Now go ask silly questions on the Yamaha thread.....  ;D

So I got mine back after the engine overhaul. Started first kick, and what was noticable was how little engine noise ther was compared to previously. So I took it on a lekker dirt ride all up hill and down dale about 100km, an I am now draining the oil and will replace the oil filter.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 04:26:55 pm
I'm going to fetch my bike just now........ Awesome!
still waiting for mine  :xxbah:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 30, 2011, 04:29:11 pm
Oil and filter changed, now just need to find an excuse to go and ride again!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 04:34:04 pm
What did you have done to your motor DeepBase?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 04:45:18 pm
At least my plastics and some other goodies have arrived  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 30, 2011, 05:00:32 pm
What did you have done to your motor DeepBase?


I farked it up by driving from Carnavon to Magaliesburg in 1 day without checking the oil. The bike ran 100% the whole time. When I tried to start it again a few days later, nothing, no compression. So what has just been done is new piston, rings, bearings and valves, so basically a new engine. It cost a bit but I'm looking forward to lots more kms from this bike.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on September 30, 2011, 05:03:24 pm
At least my plastics and some other goodies have arrived  :biggrin:

Cool, looks like you're going to have fun putting everything together. Great platform to start with.  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on September 30, 2011, 05:13:30 pm
Yeah, I cant wait, only prob is Im leaving the country for about 5 weeks, can only start when i get back....
I want to have my clutch sorted it was slipping a bit, also want motor stripped and everything checked, she used no oil on a JHB to EL trip so I think its all good.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 02, 2011, 05:48:50 pm
Woooohoooo!!!! FINALLY! :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 03, 2011, 06:38:10 am
Awesome......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 03, 2011, 11:02:28 am
Oh maaaan thats pretty ! Sorry about not coming through with the tank mount pics yet .... too many distractions , not got near the bike yet !

If that were my bike ....I'd hang onto that fairing setup .... nothing wrong with it .....sweeeeeeeeeeeet !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 03, 2011, 11:05:54 am
DeepBase you owe us a pic pleeeeze !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 03, 2011, 11:36:40 am
Here you go.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 03, 2011, 03:27:53 pm
Oh maaaan thats pretty ! Sorry about not coming through with the tank mount pics yet .... too many distractions , not got near the bike yet !

If that were my bike ....I'd hang onto that fairing setup .... nothing wrong with it .....sweeeeeeeeeeeet !

Fairing rattles to pieces offroad and is not "crashable", I will still be able to go back to original if I change. But will prob sell off the plastics.

No worries about tank pic, Im flying out tomorrow to prepare my boat.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 03, 2011, 03:29:32 pm

Here you go.....
[/quote]
Shjo,  :drif: that is a pretty machine..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 03, 2011, 03:33:12 pm
 :3some:

So next week I'm riding it for about 8 days to the bash and then back through Nam and Bots :thumleft: I just need new tyres and I'm ready to roll!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 03, 2011, 03:40:47 pm
Im envious indeed.....
Enjoy it bud, Im off to cross the Atlantic.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 04, 2011, 12:54:13 pm
DB, I am looking at what I consider to be the ultimate factory adventure bike ever made. Awesome !!! Serious perve !!!

WC , blue skies and tailwinds bud ... don't bump into anything.

I've been tidying my workshop , some seriously offbeat paint violation is about to strike that 90's white and blue in the heart ...all will be revealed.

Once you have discovered and mastered Krylon's 'fusion' technology , an adhesion promoter for Polyolefins , no motorcycle plastic part is immune to a through bastardising ..... :pot:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 04, 2011, 01:15:23 pm
I don't know why Suzi doesn't still make a DR variant like this. As soon as anyone buys a new DR, they throw away the stock tank and put on an larger one, buy a bash plate, build a rear carrier, but all of that stuff was standard on the DR650R. Makes no sense.

Lets see a bigger pic of your bike Veemax?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on October 04, 2011, 06:04:56 pm
Oh maaaan thats pretty ! Sorry about not coming through with the tank mount pics yet .... too many distractions , not got near the bike yet !

If that were my bike ....I'd hang onto that fairing setup .... nothing wrong with it .....sweeeeeeeeeeeet !

Fairing rattles to pieces offroad and is not "crashable", I will still be able to go back to original if I change. But will prob sell off the plastics.

No worries about tank pic, Im flying out tomorrow to prepare my boat.


I would also leave it original  - it's not like it's a regular, common DR - that's a rare special one - in SA at any rate
(& just 'cos I can - here's a pic of some more rare & special DRs - mine & DR_BIG_750  DR Bigs )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: GlenInk on October 04, 2011, 06:26:24 pm
Woooohoooo!!!! FINALLY! :biggrin:

Nice ride WC !  :3some:  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 04, 2011, 09:08:40 pm
DB , you wanna see a bigger pic of WHICH bike ? The 94 I posted up here, if I post my 2007 you see in my side bar, that's not allowed on this thread .... I posted it a long time back as PLAB ...( wonder if I can search for that ? ) .... somwhere in open forum....PLAB stands for Personalised Lightweight Adventure Bike btw ... even the bar ends are aluminium to save 700g !

But here I don't wanna get flamed for putting up a >96DR  !!!  :mwink:

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 05, 2011, 09:13:42 pm
Wildcoast , I know you're sailing some wild yacht across the pond, but I just wanna put this up for yer before I forget, I have closeups with a tape measure, but here's a full frontal nude showing where the 94 'SER' s tank rubber titties are , for your camel tank considerations ... more detail where this came from, but I don't wanna bore the locals. All the white plastics I took off ... previous owner powder coated the frame...I am about to undo some of his efforts....white and blue , while OEM and fetchingly 1990's....is a bit limp wristed for where this bike will be at home.

(http://i971.photobucket.com/albums/ae199/Veemax/ForumOldDR.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 05, 2011, 09:16:24 pm
Lekker. Not on the pond yet , sitting in v and a waiting for some gear and paperwork, thanks bud I can use that.... :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 05, 2011, 09:25:22 pm
I see you online ....so here's a closer one

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_4983.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 05, 2011, 09:32:19 pm
As far as I can see, or remember the frames are identical, only diffs are rear footpeg hangers, bash plate and fairing mounting brackets, if you can make a pre 96 acerbis fit a post 96, I should be a for away  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 05, 2011, 09:43:01 pm
If you can fix a broken mast mid atlantic ..... you can put any blerrie tank on a thumper : )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 05, 2011, 09:45:08 pm
If you can fix a broken mast mid atlantic ..... you can put any blerrie tank on a thumper

this one has no mast  :mwink:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Ganjora on October 07, 2011, 05:59:48 am
hey DB9,
the bike looks great,
engine issues all sorted now?
what was the final cost?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on October 07, 2011, 07:55:00 am
The fitment of the Acerbis tank onto the DR650SE was described on HUBB. Can't remember the author's name but he's even got drawings for the necessary mounting bracket.
You have to modify the seat too.

All in all it's a modification not too difficult to be considered and definitely worthwhile if you look for a ~500km fuel range tank for a reasonable price.
The Acerbis IMHO is also vastly superior to the Aqualine in design, fit & quality.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 07, 2011, 08:11:53 am
In an ideal world, I'd like a > 500km tank, but also the big plus of being able to magnetically secure a tank bag. You'd have to be a little crazy to fix any kind of anchor points to a plastic tank ... but I would consider this a big plus , anybody got a suggestion ? My only thought is to pass a sealed bolt right through, from the inside .... meantime I'm keeping my 17 litre metal tank as it can eek out 400km and my stock Oxford tank bag works well with all it's magnets lekker vas. But the Dakar with the 21 litre metal tank and kickstart is the right bike, right out of the factory.  :crybaby2:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 07, 2011, 08:17:57 am
Woooohoooo!!!! FINALLY! :biggrin:

Very very lekker.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 07, 2011, 08:23:53 am
Lekker enough to STEAL. I don't care what my wife says about No More Bikes. If I see one of these Dakars for grabs I'll buy it and hide it!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 07, 2011, 08:35:43 am
Watch this spot for pics of my DR 650R.

Changed the front fender to Polisport - Yes yes I know its not standard but I don't want to keep it all standard. Carbon Fibre Wrapped side covers and tail piece.

the bike wasn't well cared for cosmetically and I am trying to get all that sorted over time.

The colour is black with kind of lilac graphics - original this is.

So maybe by Monday I post a pic.

My XLV750R - this I am doing all to keep standard seeing as there were only 500 limited editions built in world with about 50 still doing service.

Does someone know Jason at Dirtworx that can ask hin to give bike some special attention and get it back to me soonest.?

At moment it is with Schlowy for HID and LED's.Looking good.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 07, 2011, 04:32:49 pm
Looking forward to the pics SuperDave, and then there were 4  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 07, 2011, 05:18:59 pm
SuperDave , we wait patiently !!! Look forward to this thread all the more now !

Meantime , I  warily post what two days ago was a white bike that used to have pink and blue highlight ....nooooit !

Ok, so now the frame looks odd , don't worry, that'll get bastardised too !!!

See what happens when a rookie discovers his cheap Chinese spray gun ! Eeek. Behold my first ever spray job. Be kind  :o

(http://i971.photobucket.com/albums/ae199/Veemax/07Oct2011.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 07, 2011, 06:42:56 pm
Wow. Looks awesome. The frame matches the seat and the fork boots. Looks nice
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 07, 2011, 10:15:44 pm
Some pics of my DR so far.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 08, 2011, 07:59:56 am
SuperDave , we wait patiently !!! Look forward to this thread all the more now !

Meantime , I  warily post what two days ago was a white bike that used to have pink and blue highlight ....nooooit !

Ok, so now the frame looks odd , don't worry, that'll get bastardised too !!!

See what happens when a rookie discovers his cheap Chinese spray gun ! Eeek. Behold my first ever spray job. Be kind 
That spray job looks pretty awesome, what exactly is that colour called? You going black on the frame?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 08, 2011, 10:00:07 am
Hey SuperDave , all the bits are there man. Nice to see yet another oldtimer in capable hands busy receiving new life !! Go for it !

Ja to explain my attempt at a respray ...  (1) CLEAN and CLEAN again all the plastics , in the bath ! Until the surface is squeeky, then rub down with 1000 grit waterpaper to break the shine ( 2) Apply one light coat of Krylon Plastic Primer and let dry completely ( 3) Top coat is Velvaglo !!! Dirty Khaki. Reduce 10% to 20% with Turps. Velvaglo choice is based on the fact that it's a self-crosslinking polyurethane, thats tough as nails, and being thixotropic is less prone to sagging and running compared to 'normal' paint. It dries slowly but levels well. It's matt, which is what I wanted, and also, it's easy to repair/retouch with a brush at any later date, unlike two-pack systems. I applied about 3 coats velvaglo. ( 4) The tank , being steel , was easier, I used a sanding disk to chomp through the decals to base metal, then rubbed the whole tank down with 400 grit. I sprayed on Velvaglo direct, about 3-4 coats.

Before starting out I tested the 'system' on the disk guard, did tape adhesion tests and rub /scratch tests and then petrol rub tests , and the paint held up very well. The Krylon primer is rattle can stuff btw ! It takes 5-7 days to achieve full adhesion. You could use Krylon Fusion plastic paint colours , I've done this on a farm bike, it works, but it's not as tough/scratch resistant as Velvaglo.

My aim is to make a bike that ultimately is completely unable to corrode , can be touched up , that blends into the environment of my 'farm' ( wild space )  , so that when I'm kicking back with a beer in the bush, my bike doesn't scream colour at me. The antithesis of an Orange KTM, if you like. I also think that when travelling Africa, the less attention you attract, the less ostentatious you appear, the better. A bike that fits into the bush will go some way to not attracting attention or looking like a million dollars. Ja, so I'm a strange one eh !  :patch:






Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 08, 2011, 10:08:51 am
The bike looks  :thumleft: understated, yet classy, thanks for the technical on the paints, need to spray my tailpiece and side-covers white when I get back.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 08, 2011, 04:38:57 pm
I tried the Rust O leum Plastic paint that is not supposed to need primer.

Some one was lying to me.

The paint is also not hard wearing and i like the velvaglo approach.

In fact I used Velvaglo on my cupboards at home - my own mix and it looks so mahogany people remark how cool it looks. Used a roller here and finish absolutely ripple free.

Hoping you use Hammerite on front forks and rear swing arm. I too am in the quest for a scratchproof  good quality finish.

Love your bike's colour.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 08, 2011, 04:50:53 pm
SuperDave , we wait patiently !!! Look forward to this thread all the more now !

Meantime , I  warily post what two days ago was a white bike that used to have pink and blue highlight ....nooooit !

Ok, so now the frame looks odd , don't worry, that'll get bastardised too !!!

See what happens when a rookie discovers his cheap Chinese spray gun ! Eeek. Behold my first ever spray job. Be kind 
That spray job looks pretty awesome, what exactly is that colour called? You going black on the frame?

Black frame for sure. Frame needs lots of tlc.

Colour is black on tank, carbon fibre on side covers and rear tail piece

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 08, 2011, 11:20:22 pm
Ja general consensus is I must go black on frame. Black it is. And yes, Hammerite. I have an R&D square of metal , with 4 quadrants painted with 1 x coastcote , and 3 hammerites , gloss, satin, and that 'forged' look with a flick of silver in it. I've let it dry for months. The hammerite takes FOREVER to develop resistance properties, but it's well worth the wait. Retained solvent is a bastard, but once it's out, there is no more 'plasticizer' effect, and the stuff is damn tough. The satin wins hands down for looks. Satin hammerite black it is. But it can take weeks to let go it's slowest solvent, until then, it will appear cheezy under yer fingernail !... Again, patience will win. Oh,  today I painted the bash plate to match the panels ... uncoventional perhaps, but it balances up the bike nicely.

I've just come home from Simonstown late at night on an open Ou Kaapse Weg , under moonshine, with the missus on the back. Man, these old DR's MOVE !!! It's odd, I have a Tiger 1050 and Bandit 1200 , but this ole DR is the bike I wanna ride. Why is that ????  ;D ;D ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 09, 2011, 07:51:12 am
Does anyone know a place to get tail light lenses? I was riding yesterday and picked up a bit if fencing wire that wrapped around the back wheel and broke the tail light? I'll try Suz, but they don't seem to have any stock of body bits for old DRs.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 09, 2011, 09:00:07 am
Aw, bad luck mate ! Damn.

My first search would be to a used spares/breaker with (broken) sample in hand. That's gotta be a common 'bin' component. Ultimate fallback position would be to shop offshore , but logic says its common enough to come up with a part here on home soil ?

Be glad it's not a KTM640. I had to pay R860 for a tiny bit of red plastic !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 09, 2011, 09:02:11 am
You know what ? I can't see properly from your pic, but that looks suspiciously like the same shape as a < 2006 KLR lens ....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 09, 2011, 09:36:52 am
No, its different, the rear mudguard is a different shape and the light is kind of inside the mudguard, not on top. You will be relieved to know though, that yours is the same as a DR200, and I have one of those spare lying in my garage.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 09, 2011, 09:49:34 am
Know this site ?

Looky here ....

http://www.cmsnl.com/suzuki-dr650-s-1990-1991-usa_model15961/partslist/84222.html
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 09, 2011, 12:14:47 pm
Ok, 29 Euros, not too bad. I'll see if Suz have on Monday, otherwise I'll order it from them. Thanks!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 09, 2011, 12:26:50 pm
hey DB9,
the bike looks great,
engine issues all sorted now?
what was the final cost?

Its running sweeet now. I just had the jetting sorted out so the fuel consumption is down from 12km/l to about 17/18km/l. The rebuild cost me 8 grand, which is not bad seeing as the engine is essentially new now.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 09, 2011, 04:26:29 pm
Snap, top end rebuild from base gasket up , + new cam chain, + new clutch parts also 8 grand thereabouts. Had a spanner on the crank for a valve check this week .... oh so THAT is how the compression should feel  :D !!!!!!

Going back to carbs though , thanks to Derek at Motolab in California, I have brand new plastic slide guide, and plastic slide , en route, if your slide and slide guide are worn , any carb fixes you make will not last, soon it'll have needle/nozzle wear and you are back to off-idle-rich-bog-city.

I also intend to block one of the two slide holes to reduce slide flutter, and therefore wear. The 96+ DR's have one hole for a reason !!!

The two holes / premature slide wear , is a known old-DR issue , Motolab says. Very much so for those with a high in-traffic usage.

IMHO, to enjoy an old thumper to the full , the carb must be cock-on.   These DR's are infamous for Sudden Death, it need not be like that ... thanks to Derek Capito , parts not even listed in the microfiche can be obtained !

When I've got it all on the workbench, I'll detail the Before and After to share my learnings , ... if there is good value in attending to this level of detail.





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 09, 2011, 09:40:11 pm
@Deepbase9

Sorry about your DR lens.

Will you still be leaving on Tuesday???

If so what time? Or would you prefer riding alone?

Would like to ride with you on the route you have chosen.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on October 23, 2011, 05:55:41 pm
In an ideal world, I'd like a > 500km tank, but also the big plus of being able to magnetically secure a tank bag. You'd have to be a little crazy to fix any kind of anchor points to a plastic tank ... but I would consider this a big plus , anybody got a suggestion ? My only thought is to pass a sealed bolt right through, from the inside .... meantime I'm keeping my 17 litre metal tank as it can eek out 400km and my stock Oxford tank bag works well with all it's magnets lekker vas. But the Dakar with the 21 litre metal tank and kickstart is the right bike, right out of the factory.  :crybaby2:

I just had a thought & went back & found this post..
Surely its possible to get a set of '90 & earlier DR-Big tanks to fit on a DR650 - they're metal - so your tank bag will work & they're 14.5 litres per side - ride conservatively & you'll get 500km from them - I do
plenty on fleabay...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 31, 2011, 09:34:24 am
MMm ....thats a possibility I never thought of , good lateral thinking ! I'll need to find a DR BIG to ponder and measure ...

Meantime my brand new carb parts arrived from Motolab

NEW slide , slide guide, needle, nozzle.

Which means my 18 yr old DR will soon ride like it came out the showroom in 1994 , I'll post here details of worn vs new slide etc , so others can see how much wear occurs down the years.

Derek Capito at Motolab is a good contact for us oldtimer thumpers restorers , he can access Mikuni parts not even on Suzuki's microfiche.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on November 03, 2011, 10:03:04 am
Progress pics after some black and then some more black ... I stirred it up a little here : ) ....heh heh heh

http://www.wilddog.za.net/forum/index.php?topic=82592.0

Now I need to turn my attention to the carb, but there no rush as the bike is running great for now, until the needle wear that is ... which will be quick as the slide is worn ....



(http://i971.photobucket.com/albums/ae199/Veemax/Image1-1.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/Image3-1.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/Image2.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on November 03, 2011, 10:04:10 am
Awesome!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on November 03, 2011, 12:19:45 pm
Beautiful
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on November 13, 2011, 06:52:34 pm
My wife decided my bike makes a nice change from painting ceramic coffee mugs ....

(http://i971.photobucket.com/albums/ae199/Veemax/Lizard.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on November 14, 2011, 08:06:51 pm
very nice too
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on November 19, 2011, 11:26:26 am
Hi guys

Thought I'd share this pic showing my project bike being field tested.  > 1000km ride , NOW it's run in ! And what went wrong ?  The tailight/stoplight connector wasn't clicked in properly. These are the bikes to love, keep, and cherish, if you are lucky enough to own one.

Do a good job getting it up to 100% , and never let go.

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5127.jpg)


Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 01, 2011, 02:29:02 am
Geez Veemax your bike looks friggen awesome, cant wait for time to start on mine.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: madmike999 on December 01, 2011, 05:44:59 am
hello there,

a mate of mine has a 86 DR 600, but his rear rim is totally worn, any one know of a rim lying around somewhere. He does need the rear rim to be complete.

cheers :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 01, 2011, 06:26:40 am
Madmike , I'm guessing here boet, but the old DR rim is quite likely the same as the new DR , and rims are generally what I would describe as a 'bin component'

It can't be hard to source. Sorry, I don't have one just lying around , but this will not be an insurmountable challenge if he puts in some research.

Odds are good one could order it over the counter at Suzuki , as long as they have the microfiche.

Failing that he must try the likes of Ron Ayers / Alpha Sports / CMS , but this is not a show stopper ...  unlike a rare engine component or something electrical ....

I'd begin by seeing if the rim is the same as the >96 DR , if it is , life gets instantly easier.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 12, 2011, 04:58:14 pm
Hi all

Volroom is about to join the legion with a great 95 he found in CT , 19 000 miles for R19k ! I tested the bike and it looks like he has a great deal ... lets see if he joins us here shortly ... he has yet to get the bike from Slaapstad to Gauteng but there is a plan , WD's are kind people , someone has offered him help over Dec.

Meantime I've pimped out my scoot some more , some last pics before it goes into the workshop to receive it's new carb innards which I've been procrastinating over ... I mean, why do today, what you can put off until tomorrow ?

Notes: (1) Skerpioen !!! , (2) extra 25mm aluminium bar added to give more stability to my bag ( it also fills that hole betwixt seat and rack ? ) , and (3) A 40mm Code 3 irrigation pipe takes the shine off the upper fork stanchions ... old farmer trick.


(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5258.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5260.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5259.jpg)




Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 12, 2011, 05:02:18 pm
And a last side shot before it goes for surgery ...

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5261.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 14, 2011, 01:54:53 pm
Pics taken of radical slide flutter , with side-by-side's of old vs new parts , look at the wear surfaces ...see how much material has vanished.

Anyway , it's all NEW now , should make for bye-bye all erratic behavior , sudden-death , and a much happier beast when stuck in traffic.

Imagine trying to set optimum idle with the air sucking past that slide at full vacuum ?!  Well, with new parts , the needle/nozzle should last until the petrol runs out .... God help us...

Our older DR's are one of many bikes using the BST 40 , so this problem is not just ours ....KTM640 ....new DR..... even the GSXR11 's and Bandits etc .... so help out yer mates

(http://i971.photobucket.com/albums/ae199/Veemax/BST0.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/BST1.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/BST6.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/BST5.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/BST3.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 14, 2011, 03:58:50 pm
So Motolab now has the spec and we can all order this stuff if needed?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 14, 2011, 04:36:26 pm
Pretty much , yes. Like I say you can get the emulsion tube here , and the needle , but you might as well just use Motolab as a one-stop for everything. Cool thing is the parcel freight is as light as a letter ! : )

Derek appears to have masses of data for slide tolerances etc , I know no better resource out there.

I'd like to know how he accesses the inner sanctum of Mikuni , but that's his business !

I've just this second returned from a test run. My bike is running like it came out the showroom , no erratic behaviour or spitting or coughing off, it's WONDERFUL : )

From the big-end to the airfilter is now brand new. This bike is SO worth the effort !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 14, 2011, 04:40:16 pm
Sounds like what I need, surging at low rpm and a very wierd clutch slip at high rpm???? :xxbah:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 14, 2011, 07:03:32 pm
Surging : Mmmm , could be a number of things. You'll have to open up to check needle/nozzle wear , needle position , slide wear , float height .... I found the float height changes as the float needle rubs it's way into the brass tang, should be 14.7mm +/- 1 mm , it could be too high now ... cause rich off-idle symptoms ...combine this with nozzle wear and you have a sick, surging puppy.

You can get away with a worn slide , but long term it's a good thing to sort.

Clutch slip : Many many people assemble this clutch WRONG , there are two steel rings and one special friction plate that confuses the hell out of many folks. It's the same as a Suzuki LS650P Savage clutch too , I've had now TWO of these on the bench in the last year, BOTH were a disaster ! I'm willing to bet your clutch slip is related to this being put together wrong. Dive in there and look , you might be able to fix your clutch by just putting the sequence right. You have the microfiche ?

Are you going to have some workshop time soon ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 14, 2011, 07:13:17 pm
Yeah , serious workshop time, waiting for my tank, still looking for a pipe, and a few bits then its serious re vamp time, will strip carb , doubt the clutch has ever been touched as the bike has about 20k km on her.

Will have clutch done, check out the top end of motor, wanna do shocks (wilburs) carb sorted, single exhaust can, crash bars bash plate etc, new tank, plastics and re-spray, braided hoses, handle bars, vapour comp etc, will be a new bike
 The idea is to make her reliable, crashable and longer fuel range.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 14, 2011, 07:16:29 pm
Brilliant ! I like an ambitious DR man !

Here's the clutch detail I'm on about ...

(http://i971.photobucket.com/albums/ae199/Veemax/Clutchassembly.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 07:30:10 am
Veemax do you have a good site for the workshop manual download? Been trying to source a haines manual but threw my toys with a certain well known bike shop yesterday due to promising to source one and not delivering after a 12 week wait!!!! :xxbah:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 15, 2011, 07:49:25 am
I have one for my bike, its kind of big though, maybe I can make a plan to get it to you.

Here: 25MB....  http://www.dreamlodge.co.za/1990-1995_DR650_Service_Manual.pdf  (only download in about 1 hr, busy uploading at the moment....)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 15, 2011, 07:51:23 am
I find these yahoo groups VERY Tedious , the interface is crap and dates about 10 years , but join this group and you can access their files, you'll find it there...under files / "Pre 96 DR 650"  , posted Apr 20 2008 , there are THREE .pdf's so be sure the year of your model before downloading , they are 90-91 / 92-94 / 94-95 .

http://sports.groups.yahoo.com/group/DR650/

There are 4300 odd members so it's quite a good resource, but man , what a clumsy way to communicate !!!!





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 07:53:53 am
Deepbase that would be awesome, just let me know what it will cost, CD, courier, your time etc etc  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 07:55:41 am
Coooool, I'll get the missus to download that one at work  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 15, 2011, 08:00:57 am
Only 2 MB or so .... quite well compressed !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 15, 2011, 08:04:46 am
Sorry , around 24 MB
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 15, 2011, 08:06:37 am
Only 2 MB or so .... quite well compressed !

Patience, the other 23MB is not uploaded yet!

Check this out DR600 - R12500. Bargain! http://www.wilddog.za.net/forum/index.php?topic=86150.0
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 08:07:22 am
I think the motors will all be much the same, just e-start may differ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 15, 2011, 08:08:30 am
I'm pointing to the wrong folder, grab the four-part download  under Files > Pre96 DR650 > Pre96 DR650 Service Manual , that's the one manual that's got it all , there are amendments at the back for specific years and markets , thats the goen !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 15, 2011, 08:10:20 am
I think the motors will all be much the same, just e-start may differ?

I doubt its an electric start, probably a kicker like mine.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 15, 2011, 08:12:57 am
DB9 : I like this : out runs my sister's BMW F650 Dakar. .....Aint that the truth !!!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 15, 2011, 08:15:04 am
DB9 : I like this : out runs my sister's BMW F650 Dakar. .....Aint that the truth !!!!


 :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 08:17:35 am
Mine has an e-start, no kick start and twin pipes!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 15, 2011, 08:21:06 am
Mine has an e-start, no kick start and twin pipes!

There's nothing that impresses the women like kickstarting a 650 first kick! ( its also kind of kak when everyone stares at you trying to kick your reluctant engine into life though...  :laughing4: (Fortunately that rarely happens!))
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 08:24:50 am
There is nothing that impresses a women less than helping you push start a 650 e-start when the battery is flat  :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 08:45:47 am
Just to keep the flag flying
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 08:48:05 am
Front
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 15, 2011, 08:55:48 am
I have one for my bike, its kind of big though, maybe I can make a plan to get it to you.

Here: 25MB....  http://www.dreamlodge.co.za/1990-1995_DR650_Service_Manual.pdf  (only download in about 1 hr, busy uploading at the moment....)

OK, upload complete:  http://www.dreamlodge.co.za/1990-1995_DR650_Service_Manual.pdf
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 15, 2011, 09:03:36 am
 :thumleft: :thumleft: Excellent Can access direct from the web, thank you very much
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 23, 2011, 02:30:25 pm
A few questions for the experienced DR maniacs here, has anyone done any suspension upgrades? If so what was done and results?
Secondly, as I am binning my fairing I need somewhere to attach my front indicators, pics of your set ups would be much appreciated.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on December 23, 2011, 04:01:13 pm
A few questions for the experienced DR maniacs here, has anyone done any suspension upgrades? If so what was done and results?
Secondly, as I am binning my fairing I need somewhere to attach my front indicators, pics of your set ups would be much appreciated.

Firstly - I call dibs on your fairing if it really does get binned
Secondly - I was in a similar predicament a few bikes ago - I ended up going to builders & buying drainpipe attachments - you know, the kind you'd use to fix the downpipe to a wall - that consists of 2 half circles of aluminium with a nail thing on one half. I chucked the half with the nail thing away & bent the other half around the fork & then slipped a cheap motrix indicator through the holes. Brackets all done for R6 a side.

I'll see if I can find a pic to post
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 24, 2011, 05:28:52 am
A few questions for the experienced DR maniacs here, has anyone done any suspension upgrades? If so what was done and results?
I put Wilbers progressive fork springs from LeCap up front and they made a lot of difference, less sag and much more solid feeling on the dirt. The back is stock, seems fine to me, no complaints!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on December 24, 2011, 07:29:11 am
A few questions for the experienced DR maniacs here, has anyone done any suspension upgrades? If so what was done and results?
I put Wilbers progressive fork springs from LeCap up front and they made a lot of difference, less sag and much more solid feeling on the dirt. The back is stock, seems fine to me, no complaints!

me too - & I agree
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 24, 2011, 08:14:17 am
My rear shock packed up resulting in me riding on coil spring for almost 1000 km. Going to rebuild shock and put about 7,8mm per kg spring. Stock is 6. May modify to nitrogen.Given my weight this calculates as correct spring tension. It may be a little too firm on tar. Not sure and still invvestigating. Up front I will also do progressive springs with Nitro Conversion.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 24, 2011, 09:08:15 am
I have stock suspension fore and aft on both DR's old and new , but in both cases the rear spring is wound up to the minimum length preload spec. ( for my 83-86kg.) What I DID find on the oldtimer is that the fork spring had lost about an inch overall length from the free length spec. I've done nothing about it yet , but when I get a chance at my fathers lathe I'll conjure up some spacers and that will be good enough for this bike , as I'm not racing anyone : )

When I start taking luggage seriously in 2012 I'll review the suspension.

On my KLR a stiffer rear spring transformed the bike from a marshmellow, the stock spring sagged away most of it's useful travel , I think the wee Japanese engineers all weigh about 60kg !???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 24, 2011, 07:43:41 pm
60kg with full kit and luggage. I weigh 90odd kg plus luggage could get us up to about 110kg. Shock definitely not meant for my weight.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 26, 2011, 08:17:06 am
Thanks for the input folks, so with a bigger tank (25Liters) and my 100KGs, wilburs the front , pack light and go on diet.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 26, 2011, 08:24:48 am
I would be looking at the Acerbis long range tank. 26.4 litres. Landed cost about R2800 incl postage. Excluding Vat and Import duty. Makes it quite expensive though around R4500. Or could stick with current tank of 16 or 17 liters.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 26, 2011, 08:47:44 am
Looking at the Acerbis for sure, can get one at $212 plus $75 for postage, vat at 14% so about $240 Thats R2000-00 odd, under R2800-00 with postage, you think import duties will bring it into the 4.5K region?????

I want the long range tank for sure as the fairings are going, offroad the rattling and headlight bulb breaking was driving me nuts.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 26, 2011, 08:54:29 am
I think import duties will add 40% taking it up to about R3800.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 26, 2011, 09:01:56 am
Such is the cost of progress, any suggestions on who can build a decent bash plate, crash bars and lightweight soft luggage frames in the JHB area? (north if possible)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 26, 2011, 09:39:39 am
I do have. Very reasonable with price and does excellent work. Also WD member. Not sure of his forum name but have his tel no. If you interested can get you more info.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 26, 2011, 09:56:57 am
I would appreciate his details very much thanks, its time to get the show on the road!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 26, 2011, 10:04:57 am
Will send you PM later when on pc. BB not support PM.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 26, 2011, 10:14:36 am
thanks :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 27, 2011, 07:12:49 am
There is supposedly no import duty on motorcycle spares as such, they can charge you VAT , and a handling fee , is all.

I've brought in shocks, bash plates, tanks, pipes, bars, seats, pistons, filters, brake shoes etc in the last few years and have never paid duty.

Under the GATT agreement , all motor and motorcycle parts should be free of duty, I think. Tires maybe not, I dunno, there will be exception items no doubt , to protect local interest.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 27, 2011, 07:18:49 am
Well thats about a thousand bucks worth of good news  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 27, 2011, 07:24:12 am
I recently imported decals for my Honda Blackbird and was charged duty.So dunno?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 28, 2011, 07:58:13 pm
If you give customs a chance they will find their own tariff heading and whack you with duty. When in doubt get the exporter to specify a tariff heading on the invoice, or alternately ask them to specify on the invoice something like " Motor Cycle Spare Parts " which leaves no wiggle room for customs.

I've gone so far as to include specific comments like " For laboratory weather testing only " or " for research purposes " , or for "personal use motorcycle spare parts only, NOT FOR RESALE in South Africa " etc etc. Give 'em hell !

NEVER bring in TWO of the same thing of they will "deem" you to be re-selling.

But under the General Agreement on Trade and Tariffs , motorcycle spare parts are duty free and that's IT. Don't let the farkers get away with it, thieving bastards take enough revenue from us in every ...single....other.....fucking.....aspect....of...our....miserable.....lives !!!!!

GRRRRR. and their ARROGANCE , gah, don't get me started !

The secret is to box them so tight , they can't argue.

If you have a friend with a Tariff Guide , it helps.  That bloody huge tome should be web-based by now, surely ? I have a friend who owns a shipping company .... he's a fellow biker .... maybe I can squeeze him for a favour.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 28, 2011, 08:13:45 pm
Love it. Thanks. Will definitely be yanking the chain aoon.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on December 29, 2011, 08:17:04 am
Check documentation BEFORE signing it off and paying. It helps if you collect at the customs PO (if possible) rather than at the local PO.

The only time I ever had problems was when the sender for some silly reason declared as "Motorsports something" which attracts import duties over and above VAT and clearance fees.
I got it reassessed as "Motorcycle spares" without any problems and without hassles within three days (incl. sending the stuff back to Cape Mail to reassess and forward back to Goodwood PO.

The important part is to calculate roughly in advance how much VAT and duties should be and ask to see the documentation before paying if they want waaaaay more than what you calculated.
You can still claim a refund for an incorrect & overpaid assessment but it's a MAJOR mission with a huge paper trail and you won't see your money soon (if ever).

Importing goods you paid for for private use or resale does not make any difference with regards to the calculation of customs fees.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 29, 2011, 08:24:33 am
I find the trick is to order a BIG box so it doesn't go to the local PO !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 08:31:17 am
Thanks for the pointers
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 11:48:04 am
Wildcoast , I know you're sailing some wild yacht across the pond, but I just wanna put this up for yer before I forget, I have closeups with a tape measure, but here's a full frontal nude showing where the 94 'SER' s tank rubber titties are , for your camel tank considerations ... more detail where this came from, but I don't wanna bore the locals. All the white plastics I took off ... previous owner powder coated the frame...I am about to undo some of his efforts....white and blue , while OEM and fetchingly 1990's....is a bit limp wristed for where this bike will be at home.

(http://i971.photobucket.com/albums/ae199/Veemax/ForumOldDR.jpg)
Looks pretty similar frame wise, acerbis should fit
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 11:52:26 am
My next issue will be mounting the polisport headlight unit, alot of electrics and brake hoses etc mounted behind the fairings will have to be moved, anyone here built up a streetfighter?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 11:53:26 am
Brake hose
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 29, 2011, 12:33:12 pm
That hose is so compact right there , can't you work around it ? Which Polisport headlight did you choose , I see their site shows 9 or so choices ( nice ! ) .

I've built up many bikes , no so much a streetfighter in the GSXR/Bandit default but I've ripped the poephol outta some bikes in my time  :ricky: , GS1000 platform was my biggest project.

I have a Flat Tracker in mind that is my next project , have my eye on a GN400 to make a 'tracker for the Missus who is a 48kg titch ... 350/44 suits her.

You can get quite a bit of stuff behind a new fairing if you put your mind to it !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 12:39:59 pm
Headlight is called the "Halo" I noticed it has extensions in the box, will give a wee bit more space, it straps on to the forks with rubber straps, may have to fabricate a bracket of some sort.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 29, 2011, 01:53:19 pm
Nice looking fairing.
I am thinking of modding bike with Kehin 39 FC MX carb, larger valves in head, change cam profile, then progressive springs up front with nitro fitting, harder rear spring with nitro mod. Wrap around crash bars, pannier brackets, modify seat adding gel.
Should give me more low down grunt with excellent handling and very good touring capability. Almost a go anywhere bike.
If I do all this I should have a bike good for another 10yrs at least.

So do I spend the bucks over time to do this or do I sell and buy something else that has most the goodies.
Problem is that I probably would need to spend similar money to get it to be a go anywhere kind of bike whilst laying out more capital for a new bike.

Dunno. What do you guys say?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 29, 2011, 01:56:42 pm
I'd say you will be so deliriously happy creating your OWN bike that some mass produced item will never ever measure up.

You know when you lose track of time and you forget to eat ?

THAT's when you are truly happy.

Building bikes from a solid platform like this one we share .... no contest !!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 02:51:50 pm
Mock up of plastics
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 02:56:32 pm
Build up your bike Dave,  :biggrin: I think I already spent a newish Orange monster on my bike and I have not even got started.
Now that cam story interests me, low down grunt under 3000 rpm would be nice
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 03:12:03 pm
An idea for crash bars!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 03:42:49 pm
That infernal front brake line runs exactly where I want to bolt my front fender on..... :dousing:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 29, 2011, 03:43:35 pm
Ooooh that's looking exciting.

I've never REDUCED a cam overlap and duration before , to move it towards what I'd call a 'lawnmower' cam. It's got to be possible.

You'll lose some top end bhp of course , might even need stronger springs for more aggressive closing.

But for me, I like the high rev surge the new DR lacks ... and if you make it a Grunter , mmmm, you start to open the dialogue of "is it not better to start with a post 96 ? "

So many bikes, so little time !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 29, 2011, 03:45:25 pm
That infernal front brake line runs exactly where I want to bolt my front fender on..... :dousing:

Bypass Surgery !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 03:48:32 pm
Was thinking its easier to make up spacers for fender attatchment, brake pipe is not flexible.
Maybe I should have taken a look at what I was in for BEFORE buying the plastics, but will make a plan.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 29, 2011, 04:14:29 pm
The carb swop helps a lot. Plus cam reprofile and we should have loads more torque under 3000rpm. And great response too.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 05:14:45 pm
Will new jets , drilling the slide and airbox mods not give similar response with less outlay?
If I can cure my surging after my re-vamp I will be more than happy, maybe new pipe, filter, needle and jets with a good tune is what she needs.

Oh ja and binning my infernal cable choke for one on the carb.

I will also need to re-plate my spokes, any ideas on that one?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 29, 2011, 05:26:51 pm
Let me finish my learning curve on the carb ! It's all NEW but I think the jet needle is still a tad lean. ( I don't have the original washer , so am a bit lost ) , under close to no-load low-rev 3000rpm trickle, it surges. It will even digest some choke under these conditions. If I can get the part-throttle PERFECT ( it's sooooo close ) , then I'll have one of the best carbed factory Oudt DR's around. I figure lift the needle 0.5mm will do it. If it still behaves like a KM640 with a hangover at 3000 , then I'll have evidence of the Best Case carb setup , and will then maybe validate more extreme mod's to the inlet ?? Lets see.  Right now the bike goes stunningly under 97% conditions and the compression with the new bore is phenomenal.

One last annoying thing I need to attend to is the oil return pipe from the head has an O-ring leak. Bitch. At least it's external, phew !
 
I think when I'm done with those two items, and some sag-correcting spring spacers up front, I'll be close to OEM mechanical perfection , which might be useful as a benchmark for you guys considering more serious engine/inlet mods.

My attention might, after that, go in the direction of the seat !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 29, 2011, 05:48:49 pm
I just sent my seat in today for re-vamp, will post feedback
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 29, 2011, 08:59:46 pm
Will new jets , drilling the slide and airbox mods not give similar response with less outlay?
If I can cure my surging after my re-vamp I will be more than happy, maybe new pipe, filter, needle and jets with a good tune is what she needs.

Oh ja and binning my infernal cable choke for one on the carb.

I will also need to re-plate my spokes, any ideas on that one?



Due tothe typeofcarb the std Mikuni BST is those mods will help marginally. The carb change makes for much more torque across the range from really lowdown and then a far quicker response on the throttle.

Can't compare the difference itappears. Carb swap is mind blowing and releases the bikes potential. Yes it is expensive todo but Ibelieve the grinfactor is all worth it.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 29, 2011, 09:02:21 pm
I just sent my seat in today for re-vamp, will post feedback


Unless they adding gel it may not be such a great result.
just did my XLV750R seat and it is better but not remarkable.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 30, 2011, 06:22:02 am
Oh yes, the carb slide IS drilled ! What I mean is this model DR has two slide holes as stock. The > 96 DR has a single hole. The thinking goes that slide flutter is reduced with the single hole, and therefore the slide wear , as I've shown earlier here !

I am tempted to add a top hole to the airbox , it sure helped my 08 DR ... maybe in the fullness of time .....

I have had only success and never a fail opening an airbox and jetting up. You need to not mind about intake noise though , but normally with an aftermarket zorst the extra decibels overcomes the intake honk : )

I also urge you not to make your bike TOO responsive off-idle ! My wife's XLX350R has a pumper carb, it's a BITCH in technical sections because its TOO damn responsive. Out there in Hereroland between the klippe and the sand and thorns, the last thing you want is insufficient off-idle control , and a bike which tears off into the bushes with a bump to the twist grip !

Super-response is for Motards and urban wheelies. Ja the taxis used to clear the way for my SM610 and then request a wheelie ...you don't want a snorting beast like that north of Windhoek ....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 30, 2011, 09:42:37 am
I hear you. All I am looking for is more torque usable at lower rpm as I believe the bike will handle tech sections better and you won't have to burn the clutch out trying.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 30, 2011, 11:01:04 am
Seems the balance between mild and wild is what Im after, I have heard the new needle from the dyno jet kit helps a bit, any comments on that?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 30, 2011, 11:09:32 am
I believe it does help but still not good under 3000rpm. Better response but doesn't appear to sort low down torque issues.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 30, 2011, 11:13:52 am
To purge the surge is my mission, Im about to do an order from pro-cycle, was wondering if the dyno jet kit was the way forward?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 30, 2011, 11:45:40 am
Purge The Surge : )

I reckon the guilty party is a hefty dose of valve overlap from the cam , combine that ( relatively high flow rate through engine at relatively low rpm ....for a thumper that is .....because of the cam ) with any less than ideal fuel/air , and you have this tendency to alternate overun/bog/overun/bog ....

So you have to get really perfect fueling to fight what the cam is doing , and even then there is no guarantee within the limits of the carb, you'll get it right.

I got massive improvement when I reset the float height, then again, another step in the right direction with a restored nozzle, then again, another step with new nozzle and new needle and new slide , now I hope for the last tweak with the needle adjustment I have planned.

If it still has elements of surging, well, thats the cam , and there's little one can do in the end except toss the whole BST carb and/or change the cam , but it's really near perfect now so I'd not contemplate that.

Like I suggested, maybe stick around to see if my last needle tweak doesn't get me surge-purge !

But you catch me a little off guard, as at 5am this morning I moved my DR into my work area to sort the oil leak on the return pipe O-ring first.

I'll sort that out and then lift the needle one shim and test ...

It's so damn close to RIGHT that I'm pretty sure I can get there, hell, my carb and engine are now brand new , it should go like it did in 1994.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 30, 2011, 11:48:42 am
Read the write up on Thumpertalk. There is a long thread. That should give you answer you require. Also look under Pro cycles FAQ. I think they suggest the Pro cycle kit and have some other answers there too.

The kit increases power and torque but the torque curve is still steep upto 3000rpm and then seems to really perform.

I too want no surge low down and that seems to be a function of how the BST carb operates unfortunately.

You can also mail Pro Cycles and they can explain it better. They have quick respnse and very helpful.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 30, 2011, 11:59:44 am
Just placed my order, dyno jet kit, mixture screw , on carb choke , Acerbis and vapour.....
Will be putting a new pipe on and watching Veemax's carb settings closely. :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 30, 2011, 12:28:56 pm
Definitely not gonna land at your local PO !!! HAHAHAHAHAAAAA.

Mmmm, bit jealous of that tank * insert green face*
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 30, 2011, 02:36:42 pm
Damn I am just as jealous.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 30, 2011, 04:07:46 pm
That's it I guess. My 1994 DR650 SER rebuild project is complete. I've fixed the return pipe O-ring leak. The O-ring was twisted like the waste band of a schoolgirls knickers. They say put it in with GREASE. They know stuff. Got to ease that thing in then work it so it settles without winding it into a pretzel.

The carb is DONE. It's hard to find any fault. It idles, it creeps, it pulls, it comes off full throttle back to idle WITHOUT STALLING , geeze guys, this has been a bloody test of my patience !

I can say this. The BST40 works when it's new. It ages fast. It dies even quicker than your piston/bore clearance when some fukwit lets the air cleaner rot and fall apart. If you make it NEW again, it works and works well. Maybe not as good as an alternative. It has a bad rap the BST , but it's the same carb on many other bikes.

It would probably benefit from a 1.2 pilot air jet to replace the 1.3 , IMHO , I read that someplace, it makes sense to me now.

Given what folks say about other carbs, if I were to do this dance again, I'd go aftermarket. However, it did only cost about R1700 all-in to replace all the wear parts, and thanks to Motolab for that, or it would be IMPOSSIBLE with Suzuki, who don't have those plastic parts to sell !

Anyway, my carb is set now to wear IN , as opposed to wear OUT. As the needle/nozzle gets worn, it will get better instead of worse, well, at least initially !

The only item left on my To-Do list for this bike is to replace the front disk which is at minimum thickness of 4.0mm , I'll take my time with that.

Maybe some fork vroeteling but no rush either.

So I have a near-stock 1994DR painted with Velvaglo Dirty Khaki , but it runs sweeeeetly , FEELS like a relatively new ride, goes like snot compared to most 650 thumpers, including my own Stage 1 '08 DR , and my all-in wallet I think is R37 000 for a bike with... mmmmm , about another 75 000km live left in it as it stands.

When I think I sold my KTM640 for R58k , I am very, very happy with my Old School Downgrade !!!!

 :ricky: :ricky: :ricky: :ricky: :ricky: :ricky:

Keep the faith gents, this bike is worth the work and the fuss.

And as I sit here the renewal notice arrives ! Yes, one full year it took.

Do It !!!

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 03, 2012, 02:20:35 pm
Is the exhaust header on the older DR stainless steel?
Does anyone have any contacts as to who does spoke lacing and plating in Northen JHB?

I have been getting mixed feedback as to what to do with my bikes frame, powdercoat or paint, any opinions on that one?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 03, 2012, 03:03:31 pm
Is header Stainless steel  - I don't think so.

Saw some ads for people doing spoke lacing in local magazine - not sureif Bike SA, or Offroad and Adventure or Dirt &Trail Bike Magazine. There is someone advertising on Gumtree that does restorations on older bikes and could probably point you in right direction.

Powdercoat I think is a tougher and harder finish. But like Veemax who used Velvaglo this is also a very hard wearing finish and should work as well - if not better as if you do chip or scratch finish you can touch it up far easier. IMO
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 03, 2012, 03:51:49 pm
Whatever coating is on my oldie header is intact. But I can share this, with my wifes XLX350R rebuild I took the ( carbon steel ) headers to my mates business with a sandblaster, then, with it down to base metal , I went next door to another company that does all manner of plating and they acid dipped it for me, I then blasted home as the rust starts in minutes ! I then used VHT rattlecan and followed the instructions to the letter, using my wifes oven for the three-stage cure process. So far so good, from deep rust to a solid intact surface.

I think if pressed harder for a better solution I'd go sandblast/acid etch/copper plate/ nickel plate

I've relaced many wheels, it's a pain in the butt, but it can be done, with beer on one side to maintain Zen-like equilibrium.

I've got a rear rubber change imminent, will use the opportunity to continue the Velvaglo disease, by spraying rims and spokes and hubs.

My final aim is to have a bike that cannot rust even if I parked it on Durban beach for a week.

I've been tearing around the Peninsula on my bike right this minute trying to make it leak oil, spit, fart, wobble, or misbehave. Had the engine blistering hot ... nothing doing.

Can't break this bike or find a fault or a leak or a problem.

With this kind of treatment a Husky SM610 would sweat coolant from the head gasket.

Keep on guys, keep on !

Oh yes, been meaning to ask, those Vapour dashboards ? Worth it ? I wouldn't mind not having to multiply and dived by 1.6 all the time  ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 07:28:13 am
The vapour from trailtech can be set for both MPH/KMPH also has revs, change lights and I have ordered a dash mount with various light lenses that will give me neutral light, indicators and another one, ..... it can also support a sensor that mounts under the spark plug that will give temperature in the head area.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 07:31:30 am
I was thinking of using hammerite on the frame , after sandblasting, velvaglow for the side covers and tailpiece in white to match polysport plastics and tank.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 04, 2012, 07:35:07 am
Can't wait to see the results Wildcoast!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 07:40:26 am
I can't wait to get on two wheels again, bit of a learning curve but will be worth it in the end, patience ,patience, but at least I have a very well informed DR support group to help me along!  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 04, 2012, 07:44:22 am
I like your thinking. Sounds like a good plan.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 07:49:33 am
I'm also sniffing around for an exhaust can, want to remove the twin pipes to get the weight down and mount a tool tube where the second muffler was mounted, something not overly raucous.... was thinking 2nd hand gsxr-1000 K1 or K2 can... so if anyone knows or hears of one needing a new home please let me know.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 08:37:23 am
I feel a kicking and screaming into the Digital Age coming , with a Vapour on my bike ...thanks, that heat sensor idea REALLY sells it !

Hammerite is GREAT STUFF , hoo boy is it tough. But dammit does it take a long, long, long time to release it's retained solvent and get develop it's full properties.

I've posted this before, but let me repeat. I made up a test plate with Hammerite/Velvaglo/Coastcote/Some arb enamel.

The Hammerite stayed cheesy for weeks.

Eventually though, you could not get your fingernail into it, and it really looked the toughest of the lot. You can't go wrong, great product , just be patient. Velvaglo is not as tough but it's anti-sagging properties help you apply a reasonable finish if you're a schmuck newbie with a spraygun like me, and you can thin with TURPS ! Cool solvent when you don't have a spray booth and have to breath some shit in! : )

I used Velvaglo for another reason, I had some in stock, I use it on my ' farm '  to paint stuff like generators and wheelbarrows all the time.

I have this very wild space in the Klein Karoo, where my wife and I and dog live like raw savages much of the year.

When all your bikes are ready, we must have a gathering there. It's in the middle of adventure biking heaven, and you'll have a true bush experience like few folks ever get these days.

There is nothing quite like staring half pissed into the flames of a fire, with something large crashing through the bushes behind you, and you have no idea what it is ..... :D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 04, 2012, 08:41:37 am
Quote
where my wife and I and dog live like raw savages much of the year.

 :laughing4: I can relate!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 08:47:41 am
Zorst Can .... Wanted on Gumtree ?

BTW there is a brilliant Welschman down here in the Cape, his name is Geoff Talbot. He runs a very relaxed retirement business from his home workshop.

He uses Staintune stainless basic canisters , and a number of prefab cones, pipes, bends, perforated tube etc to custom make virtually any exhaust configuration you want.

He's the kinda dude you give a drawing to, and your bike, and get a one-off exhaust back, and his prices are ridiculous, like R1000 ?

Maybe R1500 ?

His number is 021 531 8429

Of course there are a number of fabricators out there but few work in stainless as well as Geoff.

Here, let me attach a pic of the pipe he made for my Tiger , I think he charged me about R1400. Awesome dude.

(http://i971.photobucket.com/albums/ae199/Veemax/ScorpsNew.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 08:54:40 am
Sorry, being a twatwaffle, I should mention that Geoff could use MY bike as a jig to make a pipe for you. I need him to do an off-bike job for me on the wifes S50 Cruiser ANYWAY , so I need to go to see him regardless ...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 09:05:09 am
Now that would be a fine plan, must just measure to see if the header is the same , would certainly be interested in that angle as I'm looking at about 2.5-3k to fabricate a pipe up here!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 09:20:57 am
Here's some cross-fertilizing maybe of interest to you guys , but from my newer DR , here's a Talbot pipe up close , my whole 08DR in Dorky Shopping Mode ( top box siesahh ! ), and  an IMS clear tank, painted Primer + Velvaglo Satin Black , black leaving a .... .....hahahaha.........Fuel Guage ! : )

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5291.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5289.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5290.jpg)



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 09:26:59 am
You should post your IMS painting set-up on Advrider and DRriders websites as the yanks and aussies cant make paint stick on the plastics  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 09:39:19 am
WC ja I know there is interest in this, it's been discussed before. I tried (1) Rustoleum Plastic Paint : Fail (2) Rustoleum Plastic Primer + Aerolac Satin Black : Fail after about 1 year , and now (3) This one, ie, Rustoleum Plastic Primer , cured for 2 weeks first, then Velvaglo on top, also cured for two weeks with no gas in tank.

This latest version the Jury is still out on. Too early to celebrate. However, the theory goes this time that I EXPECT the primer to soften in the fuel vapours that transit through the polyethylene ! But letting it really, really, really DRY first,  removes all traces of retained solvent that might have been responsible for blistering in the past. (Clue: It failed mainly where the sun cooked it )

My Velvaglo test plate showed very robust petrol-run resistance , so now I hope that although the fuel might soften the primer, it basically plasticizers the polymers and keeps the Velvaglo in adhesion.

It's too early to publish, I'll invite a ton of shit on my head if I do ! But so far so good , I remain cautiously optimistic. An Acerbis tank for the old DR would look really cool pimped out painted,  if we can find a system that works, and works well !

Velvaglo is PU , self-crosslinking , it should hold against hydrocarbons for a while, and I don't mind refreshing the job if I have to.

Just not too often !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 09:44:17 am
I'm going the reverse route, paint or obtain plastics to match the tank, I kinda like a white bike.
That pipe on the new DR looks very lekker, how does it sound? (profile is exactly what I was after)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 09:55:32 am
Tank First is wayyyyyy smarter logic eh WC , ja, I bow to your Logic .  :laughing4:

To be honest when I got this pipe back from Geoff I was dissappointed, it had a squeak on decel , I think he used perforated pipe with holes that were too small.

So being the irreverand fukwit I am, I welded a drill bit to a long rod and sommer drilled the baffle right out of the end, then welded a file to the same rod, filed it smooth.

So now I have a freeflow canister.

It's not too loud , no more squeak, and has a nice bark under load.

But I had it in mind to have stern words with Geoff to use a perf pipe with beeeeeeg holes in it for future work.

Nice thing about the guy is he says if you are not happy bring it back.

That doesn't help you much I know. I must say I dig the Scorch that came with my Old DR better.

But Geoff's pipe does look minimalist and neat. Normally he places the end trumpet horizontally but I asked for it in line.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 10:01:28 am
I dont know if you picked up on my pipes the PO welded a pipe the re-directed gasses away from the number plate on the end of the can, musta had a flame up at some time.

Certainly will contact Geoff, will do measurements etc on pipe later today, but first going to go see a guy about plating my spokes , my rims still perfect.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 10:49:49 am
The best SABS Aesthetic Anomally Plate is one that's on FIRE !!!

SANS1116 is the kakkest dumb standard in the whole world. Like the wee California plate, that doesn't murder a bikes look.

I actually SPOKE to SABS once, regarding the SANS1116 , they were quite civil. I never had the motivation to take it further.

Instead I make my OWN plates , but that's illegal, they are 70% the size of SABS and I've got away with it a few times  :pot:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 11:42:28 am
Right, spoke to these guys, I must unlace rim, take spokes for re-plating myself, they will re-lace at 550 a rim  ???
How does that sound?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 12:07:23 pm
Okay, maybe I should look at a pooratech option on the spokes, 2k quote for strip re-plate re-lace and true for both rims!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 01:45:10 pm
Been checking carbs on e-bay, tm-40 pumper carbs at 250 dollars , HOWEVER I noticed that there are dual pumper carbs for snowmobiles at 120 dollars, can they be split and used individualy? I would be in for a 60 buck split cost if this could be done!!! :mwink:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 01:51:16 pm
R2000 buys a lot of bottled patience, c'marn, DIY, have the experience of success !

Make your own spoke tool , a couple garden chairs, a clamp , a khoki pen for runout highlights, lace and tension , know it's right when YOU are happy !

It's really just a mental thing

In fact, can be good therapy.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 01:53:41 pm
Been checking carbs on e-bay, tm-40 pumper carbs at 250 dollars , HOWEVER I noticed that there are dual pumper carbs for snowmobiles at 120 dollars, can they be split and used individualy? I would be in for a 60 buck split cost if this could be done!!! :mwink:

Got a strongish rand , lucky for you. I imagine a snowmobile carb might just get complicated with pre-heat and weird snow stuff ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 01:59:17 pm
The spoke saga has improved somewhat,  strip and re-lace at 350 per wheel, been advised on new spokes seeing as they 15 years old, but seeing as they only have a bit of surface rust I'm thinking of re-plating them.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 03:10:37 pm
Sounds like you've reached a viable fix , in your shoes I'd go this route. Bear in mind that those spokes will need to be retuned after a bit of settling in though .... factor that in.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 07:22:56 pm
Been playing a bit in the storage cupboard that pretends to be a garage today....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 07:26:41 pm
Everything fits on the new bars
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 04, 2012, 09:14:06 pm
Maaaaaan, hurry UP already !  :happy1: :happy1:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 04, 2012, 09:18:01 pm
Had a look at my frame today, painting can wait, she only has 17k km on her , so i'll ride the blerrie thing till the motor needs work!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 05, 2012, 07:41:52 am
WC, you are a solid reminder that a man can never have too big a fridge , or too big a garage  :imaposer:

My philosophy is to build a bike around a proven engine , if yours has ONLY 17 000km ( for REAL ??? ) , wow, you're almost home already!

Where did you get a bike that has been used 1000km per year instead of the industry average of 25 000km !!??? Old Age Home ?

SCORE !!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 05, 2012, 08:10:05 am
The bike was bought from a 2nd owner who had done one 120km trip and used it to the shops now and again after that, the owner prior to that had let her stand for a few years.

 ;D yeah that garage, thats it after my girlfriend cleaned it up to store my bike, Im unfortunately not allowed to throw anything more out, but hey I am used to small spaces, sure as hell beats working in a yacht engine room.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 05, 2012, 08:23:37 am
I have a low ceiling double garage and cram THIS lot in there with a Hilux and a Condor , 4 bikes sideways, 2 jammed between the cages, and manage to squeeze one through the door into my workshop space.

HAHAHAHAHAAA

I am EXPERT in bike shuffling ! Then I still have a 200cc plaas bike in the Karoo. So far the missus won't let me park anything in the house, dammit.

(http://i971.photobucket.com/albums/ae199/Veemax/Array.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 05, 2012, 08:29:44 am
Im sure you can get rid of the Condor , that way you can get a few more bikes.

Nice collection you have going there  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 05, 2012, 08:30:01 am
Hey, anyone need a front disk ? I'm getting one made up next week , just as easy to order 2. They use the old one as a template to follow with the lazer cutter. Min thick is 4mm , starts out 4.7 !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 05, 2012, 08:33:12 am
The Savage, S50, and XLX belong to the WIFE . I'm not above riding the S50 , goes like snot for a cruiser, very light and goes around corners too. Ja I've put a stop to buying and selling for at least a year. Too addicted to novelty ? But I need a project bike ....mmmm.....think I'll Cafe Racer that Savage ! : )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 05, 2012, 08:40:23 am
My disk is okay for now, just want braided hoses.
I will strip the remaining bodywork off today and get those "zorst" measurements to you ASAP.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 05, 2012, 11:24:37 am
Okay, progress, exhaust cans removed, tailpiece removed , can prep those for spraying.
Veemax, I think its best if I just courier the zorst to your guy and he can work from those dimensions.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 05, 2012, 01:45:55 pm
WC - If those TM40 double pumpers can work we could always sHare one a piece?

Your bike is looking very nice.

Makes we want to go out and do something similar but nit yet until I have sorted the suspension then the motor mods and Acerbis tank and then we can think about the other cosmetics.

Oh if only I had more time to work on the bike.

Wife she is not happy that my bike gets more attention than she does.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 06, 2012, 05:07:58 am
Yeah Superdave, was thinking about splitting the carbs, at 60 dollars each its a bargain.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 06, 2012, 05:28:20 am
What I know about carbs is very little, can balanced carbs be split?
Any comments from a carb guru welcomed......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Hagar on January 06, 2012, 06:46:06 am
I read that they cannot be split.  I think the pumper is only in one carb also.  This is according to what I read on internet when also considering this 2years ago.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 06, 2012, 06:52:50 am
Eish! back to the drawing board on that one then......
Superdave, what suspension mods are you doing?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 06, 2012, 07:02:42 am
Generally 2 carbs on a fitting joining them together. Possible problem is that the throttle control etc has either a left or right orientation. So probably need mods to work properly.

Might be idea to search advrider or thumpertalk to see if there is a thread on it.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 06, 2012, 07:22:44 am
Any suggestions on removing decals from plastics prior to spraying?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 06, 2012, 10:19:33 am
Any suggestions on removing decals from plastics prior to spraying?

Don't spray the (flexible PP plastics) to begin with unless it's a "Verkaufslackierung" ::)

It will come off eventually and unfortunately and then it will look really shite :-\

Best way to get old stickers off is start with carefully lifting one corner with a Stanley knife blade. You can often pull the whole sticker off in one piece. Sometimes it's tedious and they keep tearing and you have to pull them off bit by bit. They leave a ghost image of not weathered plastic underneath the sticker..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 06, 2012, 11:04:00 am
Going to have to spray my sidecovers and tailpiece otherwise with white tank, headlight cowling and handguards it will look "Maximumshitkleuren!"
Will try the veemax method with velvaglow.

Next question..... standard DR ignition, what do the two black wires do?
All the smaller (compact) ignitions I have seen at shops here in JHB (Non OEM) have 4 wires?????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 06, 2012, 11:49:44 am
Eish! back to the drawing board on that one then......
Superdave, what suspension mods are you doing?



WC - I am rebuilding rear shock and converting it to nitrogen - you know how the Ohlins look with the cannister next to shock. I am changing the spring to higher rate - in my case I weigh around 90kg and luggage normally about 20kg so spring rate somewhere around 7,8mm/kg to 8mm/kg. Std spring rate is 6,5 kg/mm.

Front end - progressive springs - not sure of the rate off hand but also fitting nitrogen adapter. You know the goodie that goes on top off the cap that allows you pump nitrogen in if shock too soft and able to reduce if shock too hard. That is the end goal for the suspension.

Spoke to Shimwells here on East Rand and they seem to have lots of experience with this.

In fact my friend with XT660 had serious tank slapper at 140km/h and went to see them - they fitted the fitting to pump nitrogen as his seals were still good. Raised the pressure up front and he says the bike is like a new bike with better handling.

CARBS
Why don't I buy the tdm 40 direct from Procycle or the other German chap. Comlete with cables etc.

Then you can buy a cheapercarb off e bay and the rebuild kit from Pro cycles. We can have cables made up here as we will know the lengths and we can do mods to throttle and the vacuum as we will have a standard to work from. Don't know if that would be any cheaper in the long run though?

Also haven't seen Dyno Jet kit for this carb which I presume would be a good mod to have.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 06, 2012, 12:36:31 pm
don't have a before and after,
but here is the graph from when i dyno'd my bike.
TM40 pumper.

http://www.wilddog.za.net/forum/index.php?topic=32071.840
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 06, 2012, 01:59:58 pm
I think the pumper will cure all bogging and surging and give good responce , dunno if it can cure the cam induced flatness below 3 k rpm, has anyone done a pumper upgrade on a pre-96 DR?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 07, 2012, 05:19:00 pm
Going to have to spray my sidecovers and tailpiece otherwise with white tank, headlight cowling and handguards it will look "Maximumshitkleuren!"
Will try the veemax method with velvaglow.

Next question..... standard DR ignition, what do the two black wires do?
All the smaller (compact) ignitions I have seen at shops here in JHB (Non OEM) have 4 wires?????

Looks like the black wires are the MAIN juice lines , the other ones do the switching, here's a pic of the diagram from the DR manual , both USA/Canada and the "Other" look the same.

(http://i971.photobucket.com/albums/ae199/Veemax/DRIGN.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 07, 2012, 07:13:45 pm
Damnnnnnn there goes an aftermarket ignition  :eek7:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 07, 2012, 08:02:21 pm
Mmm, must take some time to ring out the wiring diagram in my head ....question in my mind is.....what if you don't care about a parklight function? Can you then get away with a 4-pole switch. Something to work on .....but I'm partied out and off to put my feet up !  :bueller:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 07, 2012, 08:40:02 pm
Absolutely no rush, sprayed my sidecovers and tailpiece today.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 07, 2012, 08:43:49 pm
Kan julle slim manne my se of die ou suzuki DR600 en di nuwer DR650 se ratkas en crank dieselfde gebly het ? My broer se 650 se 5de rat het ontplof en nou die hele engine in sy moer
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 08, 2012, 01:46:59 am
Zetman ek glo die NUWE 96+  Enjin en Ratkas en eintlik die HELE bike is nie dieselfde nie, maar dit behoort dieselfde as die OU pre96 DR650 te wees!? Gaan kuier by Suzuki en vra vir hulle mooi om die microfiche's te check, dat die parte nommers dieselde is.

Kyk bietjie by Ron Ayers en AlfaSports se websites vir dieselfde. Ook CMS innie Nederland.

Ek glo nie jy gaan met 'n ou DR600 se ratkas vas sit nie ... daars nog hoop vir hom. Die ou 600 Rocks !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 08, 2012, 09:25:11 am
It never ceases to amaze me how local bike shops try to rip us off!!!!! Had a look at that Ron Ayers website Veemax, spokes for both wheels at $100-00 local guys quote 1000 bucks a wheel?????

So could prob land both sets of spokes for half the local dealers quote.  :dousing:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 08, 2012, 11:04:08 am
Ok thanx i will go and have a look ...what do you guy's think of Magnum's old 85 DR600 he want 12000  yay or nay?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 08, 2012, 11:09:44 am
Skuus nog ñ vragie jul weet ni dalk van ñ engine vir my broer se bike wat iewers rondle dis is ñ 97 suzuki freewind ma die DR650 het dieselle engine dankie vir jul hulp
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 08, 2012, 01:34:30 pm
Die ou 650 is die selvde as die freewind, nie die 650 na 1996 nie
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 09, 2012, 08:41:54 am
Going to have to spray my sidecovers and tailpiece otherwise with white tank, headlight cowling and handguards it will look "Maximumshitkleuren!"
Will try the veemax method with velvaglow.

Next question..... standard DR ignition, what do the two black wires do?
All the smaller (compact) ignitions I have seen at shops here in JHB (Non OEM) have 4 wires?????

Looks like the black wires are the MAIN juice lines , the other ones do the switching, here's a pic of the diagram from the DR manual , both USA/Canada and the "Other" look the same.

(http://i971.photobucket.com/albums/ae199/Veemax/DRIGN.jpg)

Come on B/W and B/Y are always closed except with ignition on. Ain't that difficult to figure out ???

Hint: Try to figure out what happens when you connect B/W and B/Y. If you can't figure it out try it. You will not fry your bike, promised :D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 09:24:51 am
Good morning all , had some sleep now have half a brain : ) ...... Black/Yellow goes straight into the CDI unit , so what do you think it's function is in there ???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 09:26:45 am
Oh, and it also goes to the kill switch, where it hits B/W .....definitely a way to stop ignition then ..... ????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 09:34:47 am
Something to do with the sidetstand cut out or the auto decomp/clutch lever?????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 09:38:24 am
I'll wire everything up today and leave em off and see what works  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 09:43:51 am


FSSSSSSSSSSSSSSSSS

BANG !!!!!!!!!!!

 :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 09:45:41 am
eish!  :eek7: Ping!!! Le Cap, can I fit a 4 wire ignition to this thing?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 09:56:56 am
Looks to me like if you leave the black wires open-circuit your kill switch will stop working. You could take B/Y from the CDI to the kill switch directly , to restore it's function , and bypass the ignition switch , then you can go to 4 wires ?

I didn't go to Hogwarts School of Automotive Electrics, do not trust me !

Le Cap !??

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 12:38:28 pm
 :biggrin: Ja Le Cap please I don't want  :blob8:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 12:40:42 pm
Can anyone post a link to the "BST bible" thread on Advrider here? Both myself and Volroom need to read it
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 09, 2012, 12:46:25 pm
And Volroom needs to post some pics of his new ride......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 12:48:10 pm
 :laughing4:  Ja +1000 the fellow is scarce indeed
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 01:01:41 pm
Been spraying up a few parts, Battery box, gearlever and footpeg hangers (looking for wide pegs) sidecover and tailpiece
Will spray exhaust header when Missus goes back to work so I can bake it in the oven  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 03:50:29 pm
DAMMIT  I deleted my bookmark to BST Bible Thread ! Sorry man, quick search doesn't find it either. Sh^t !

Ha ha ha world is too small I ran into Le Cap at Craig's this morning, now I've met the dude, he's even taller than in his sig.

Volroom is on school holidays so I guess he's not too close to a 'puter now. Dammit he got the deal of a lifetime, hope to see him here soon

I had to talk him down from a diversion , he nearly went to the DR800 side of the Force.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 03:51:46 pm
Been spraying up a few parts, Battery box, gearlever and footpeg hangers (looking for wide pegs) sidecover and tailpiece
Will spray exhaust header when Missus goes back to work so I can bake it in the oven  >:D

Hammerite Black or what, on the metal ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 05:06:18 pm
Yep! Hammerite black, I have some high temp black for the header, dunno if I should DIY the rust off with wire brush and drill or sandblast before painting it?

Thinking of cold galving my spokes
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: ktmmer on January 09, 2012, 05:11:21 pm
I am looking for a DR 600/ 650 motor any leads would be appreciated!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 06:18:09 pm
Yep! Hammerite black, I have some high temp black for the header, dunno if I should DIY the rust off with wire brush and drill or sandblast before painting it?

Thinking of cold galving my spokes

PIMP away man , if you are gonna violate , do it with passion !  :headbang:

Can't help with these other dudes looking for enjin's or spares bikes , but if you are really a serious restorer , have a look at Craigs List over in California. I've been helping a friend get a VS800 block from over there.

Its not impossible to import a block, but you have to know the dance.

The key thing is to get an Import Permit.

Perhaps you guys looking for DR600/650 engines can just keep tabs on this thread ...what I can do is summarise the procedure for maximum efficiency based on this VS800 learning curve ?? You'll need to wait a while.

It's time we home fixer's got wise and stopped living like we were still in international isolation , perhaps it's time some old bastard like me summarised import and banking procedures for the dummy, but first I'd have to un-dummy myself and gather the facts !

This is a very small world and there is no reason why we should limit our used parts shopping to our own soil.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 06:48:45 pm
I am looking for a DR 600/ 650 motor any leads would be appreciated!



A whole motor???? what's broken on your existing motor????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 09, 2012, 07:27:42 pm
Ek soek ok asb leads vr ñ engine DR650pre 96 my broer se engine se 5de rat het ontplof nou die engine moertoe
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2012, 07:29:43 pm
Check wat stukkend is, baie parte op e-bay
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 09, 2012, 08:00:27 pm
Jong als is stukkend gemoer dieselle soos Ganja se bike ons het so 130km/h gery toe breek die ketting en toe breek 5de rat en toe die res....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2012, 08:58:16 pm
Eina Eina Eina !!!

This is why I have my own DID Chain tool and do most of my own work . Rivet links are the only links ! ( Al issie ding hin SCRAMBLER ! )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 10, 2012, 09:05:17 am
Looks to me like if you leave the black wires open-circuit your kill switch will stop working. You could take B/Y from the CDI to the kill switch directly , to restore it's function , and bypass the ignition switch , then you can go to 4 wires ?

I didn't go to Hogwarts School of Automotive Electrics, do not trust me !

Le Cap !??



Yes B/W and B/Y are used to switch off the engine. It's a magneto ignition remember and does not run off the battery but off a separate source coil. Means cutting battery power won't switch off the engine.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: ktmmer on January 10, 2012, 10:09:50 am
I am looking for a DR 600/ 650 motor any leads would be appreciated!



A whole motor???? what's broken on your existing motor????

Yip for a project. I have a rolling chassis for a KTM, I would like to add reliability by fitting a Suz motor!  ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 10, 2012, 10:13:17 am
I am looking for a DR 600/ 650 motor any leads would be appreciated!



A whole motor???? what's broken on your existing motor????

Yip for a project. I have a rolling chassis for a KTM, I would like to add reliability by fitting a Suz motor!  ;D

Its a good thing not to many KTM okes frequent this thread, your will be burnt at the stake as a blasphemer!  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 10, 2012, 10:32:47 am
Yip for a project. I have a rolling chassis for a KTM, I would like to add reliability by fitting a Suz motor!  ;D
[/quote]

HAHAHAHAHAAA

This is very very interesting. Doen it ! Getting the chain drive on the other side will be fun.

Having recently owned a KTM640 and now with Old + New DR's , I will be lurking and looking as this absolutely grabs MY attention !

IMHO this sounds like someone building the worlds BEST adventure bike. There was a dude who made a Versys block into a 21 + 18 incher with range and all, that was close, but a Thumper approach is better to my mind. Not so many guys know that once you cross the Cubango, Cunene, or Limpopo , 650 cc is HUGE, and that 85kph is about as fast as you'll ever need.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 10, 2012, 10:37:20 am
Ktemmer sorg net dat jou ketting ni breek anders gan jy di bike moet huis toe stoot...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 10, 2012, 10:47:46 am
Ktemmer sorg net dat jou ketting ni breek anders gan jy di bike moet huis toe stoot...

Ek sal sommer volunteer om die ou met my bakkie te gaan oplaai , die projek is selfs beter as die ou hier in die Kaap wat sy GS Dakar met KTM Oranje geverf het.

Bravery deserves support here boet !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: ktmmer on January 10, 2012, 10:54:25 am
Getting the chain drive on the other side will be fun.


I have done it before, flip the back wheel over and switch sides with the brakes by welding new attachment points on the swingarm

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 10, 2012, 10:55:33 am
Yip for a project. I have a rolling chassis for a KTM, I would like to add reliability by fitting a Suz motor!  ;D

HAHAHAHAHAAA

This is very very interesting. Doen it ! Getting the chain drive on the other side will be fun.

Having recently owned a KTM640 and now with Old + New DR's , I will be lurking and looking as this absolutely grabs MY attention !

IMHO this sounds like someone building the worlds BEST adventure bike. There was a dude who made a Versys block into a 21 + 18 incher with range and all, that was close, but a Thumper approach is better to my mind. Not so many guys know that once you cross the Cubango, Cunene, or Limpopo , 650 cc is HUGE, and that 85kph is about as fast as you'll ever need.

[/quote]

For sure, I did a trip once to Malawi on my trusty CB750, and at every road block or border post the guys were amazed to see 4 cylinders on a motorbike.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 10, 2012, 10:57:50 am
James Bauer did Sani and most of Africa on a GS1000G , two wheels man, they can go anywhere.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 11, 2012, 03:54:14 pm
Right slow progress but progress nevertheless , made a workshop in the garage, fabricated brackets for new indicators, got the good news that my parcel from pro-cycle is finally on it's way, and finally sent off my "Zorst" to Geoff Talbott (He may need to look at your bike Veemax)

I also noticed the other DR's on this thread have oil cooler protection bars, mine is without, so anyone with one of those goodies lying about please PM me.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 11, 2012, 03:58:15 pm
Right slow progress but progress nevertheless , made a workshop in the garage, fabricated brackets for new indicators, got the good news that my parcel from pro-cycle is finally on it's way, and finally sent off my "Zorst" to Geoff Talbott (He may need to look at your bike Veemax)

I also noticed the other DR's on this thread have oil cooler protection bars, mine is without, so anyone with one of those goodies lying about please PM me.

It would probably be easiet just to make an oil cooler protector. Mine is just chromed tube steel. I bet you could make something really cool if you though about it a bit.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 11, 2012, 04:01:55 pm
I would if I could pipe weld  :'(
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 11, 2012, 06:58:42 pm
Hey guys, I'm loving my DR! It's like a golf witha modified engine..sort of. Understand the cam is a bit "hot". Anyways, questIon: can I upgear without the clutch. Some okes say it doesn't hurt the gears as long as you do it properly, on the DR it works much better than the GS-more smooth. What d'ya think?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 11, 2012, 08:13:37 pm
VOLROOM !!!!! Welcome welcome dude !

Guess where I have been today !?

I rode my 1994 DR650 about 400km , a lot of dirt, trying to squeeze the last out the the back tire ...

The sun is setting, and I've just rolled in, dop at hand, bike cooling in the driveway.

Guys, I have to tell you something. This is it. This is the secret. This is the bike. I've owned about 30 bikes. This is the one I love best.

The stock carb is a BITCH. Slap it into shape, and you have a BIKE man.

I've been on HORRIBLE corrugations, tar passes, single track, got lost in Safripol's forests ( shhhh!!!  Illegal ) , flat out gravel highway, fought off wind, passed Harley's, wow, what a ride.

This bike is the definitive adventure bike, and do not underestimate what happens between 6500 and 7500 rpm ....you tend to ride at 4000 to 5000, maybe a brisk 5500 .... but there's a DEVIL in there....a rev-happy smooth band of Use and Abuse, that really brings out the dark side of this unassuming machine.

I am going to sue BMW for stealing two good years from me.

KTM , great. Keep yours. Been there done that.

But if you want something different, this old DR will never grow old or stale gents.

The Essence.

Thats what it is !

Ok, let me go refill my brandy now.

*hic*

Seriously, get your bike's RIGHT guys, then we are gonna meet HERE ..... I own this, and I want to summon the Clan. Bring your DR and your tent.

(http://i971.photobucket.com/albums/ae199/Veemax/OshoekTakeAway.jpg)



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 11, 2012, 08:16:48 pm
Another for luck.

Adventure riding heaven ... is where my land is in the middle of .....

(http://i971.photobucket.com/albums/ae199/Veemax/UshkiTowerKop1.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 11, 2012, 08:48:04 pm
 :ricky: Im in +1000 , welcome volroom , about time!!!!  :laughing4:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 12, 2012, 09:10:23 am
Re the 640 with a DR650Se engine:

Take a stock standard DR650SE fit Wilbers fork springs and emulator valves, stronger rear spring / revalve if you're fat, a plastic tank (choose one of three more or less "bolt ons" or the 25l Acerbis which fits with a bit of modification.) Some accessories like a decent handlebar, hand protectors, bash plate etc.

Similar result with much less hassle.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 12, 2012, 01:38:12 pm
BST Bible Thread found ! Thanks to Volroom who reminded me I had EMAILED it to him, here goes:-

http://www.advrider.com/forums/showthread.php?t=347184
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 12, 2012, 02:54:13 pm
Excellent, thanks alot Veemax  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 12, 2012, 03:06:40 pm
Great to join the thread! but I've still got the question: upgearing clutchless - good idea or bad idea. I've been trying to get used to doing it on my GS, it's way easier on the DR. More Smooth, but is it a good idea?
Cheers
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 12, 2012, 03:35:32 pm
Clutchless shifting at speed really has no consequence , but if you crash it you'll round off the dogs on the gears. Given the rarity of these old DR's and the value of gears in the drive chain, I'll just use my clutch for all changes, save myself the mental strian of thinking about when its cool and when its risky !

Also the only person really qualified to shift without a clutch is someone who has held a syncromesh gearbox in his hand and really, really got to understand it's workings and limitations ....once you've rebuilt a gearbox or three IMHO then you get the honour of hero-shifting !

There's more to loose and little to gain ... clutch cables are cheaper than gearboxes !!!

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 12, 2012, 08:52:26 pm
Thx 4 clearing that up Veemax! Will do so
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 13, 2012, 08:04:39 pm
Reading the Bible..(BST-40), ..any dog in jhb area who knows the Bible of by heart?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 13, 2012, 09:46:27 pm
We are waiting for the Volroom Executive Summary !

Or Bullet Points ...

perhaps an Audio Book ???

 :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 14, 2012, 08:28:06 am
I watched Mondo Enduro for the first time last night  :thumleft: geez those bikes took abuse!!!!

Has anyone ever ordered anything from pro-cycle here??? Bit worried about my shipment. Only have tracking since it left the USA
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 14, 2012, 07:37:12 pm
We are waiting for the Volroom Executive Summary !

Or Bullet Points ...

perhaps an Audio Book ???

 :biggrin:




 ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:24:09 am
Had a busy few days, first order of business was to tackle the garage, the missus agreed to a mass donation to charity so I could build a workshop of sorts.......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:26:36 am
I found a solution for the front fender using plate and spacers, now the brake line is protected .....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:28:33 am
Fitted the fender and took off old mudguard ,  kinda transforms the front end.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:30:50 am
Sorted out "zorst" header and heatshield, drill with wire brush , acid wash and baked on high temp paint.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:32:59 am
Now I await my tank, vapour dash and carb goodies so I can fit,set, jippo the respective areas, then it will be the wheel areas next
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 15, 2012, 10:49:12 am
Nice progress there WC !!! Looking good man. I'm glad your workshop is progressing. I won't post a pic of my Man Cave lest it cause a divorce your side ...

: )

I've also been beavering away. I'm due for a new tyre so this spoke discussion had me wonder what lurked under the rim tape. The answer was a bit of a shocker.

Below is my attempt to bring back my rear wheel from near-death. Phosphoric acid is your friend. Naturally I now have masked all problems with Velvaglo.

Nice thing about a bike which is liberally surfaced with polyurethane,  is it will never rust again.  :thumleft:

For you tech-heads Phosporic Acid + Iron Oxide = Iron Phosphate which cannot subsequently rust. Cover THAT up and you have a reasonable fix.

Short of replacing the spokes this will do for me, the rims were straight and true and the spoke tensions all good so no adjustment  was needed. Was that NOT the case, I'd have soaked all the heads in penetrating oil for a few days rather , and tried to mobilise the threads.

Ja I know I am sweeping the problem under the Velvaglo Carpet , but I'll simply await the next time I place a big order, then get in some new spokes as a backup. Take my time. One winters day I'd get around to it.

Odds are good the front wheel looks less bad. I wish there was a better trick for tyre fitment than using bloody dishwashing liquid, which corrodes your spoke heads like this. Maybe someone knows of a PROPER lube for tyre fitment that doesn't cause rust ? Educate me. ( Que Le Cap : The Wikipedia of Tech Matters! )

(http://i971.photobucket.com/albums/ae199/Veemax/Spokes4.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 06:43:10 pm
My spokes also need attention, that's the next bridge I have to DIY, wanna either cold galv or spray them after sanding and home acid washing, may even go silver hammerite, want something I can touch up myself. What about WD40 as a lube/rust prventer?

Got my seat back, looks alot more comfy now, thanks Charlie  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 15, 2012, 09:28:39 pm
Seat looks good Wildcoast, nice job on the spokes Veemax. I want a spoke torque wrench, anyone got one or knows where to get one? You can hear the spokes aren't equally tensioned. I sprayed some q20 on the metal bits to prevent rust and accidently sprayed some on the disc's...when riding today I wondered to myself if the brakes were always so weak until I realized..will clean with hot soapy water tomorrow.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:31:34 pm
Deepbase and Superdave, what carb set-ups are you guys running at this altitude with aftermarket pipes? Any airbox mods? My carb is next on the agenda when my jet kit arrives , wanna try eliminate as much guesswork as possible....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 15, 2012, 09:34:49 pm
LOL Volroom , just don't write your new baby off with Q-20 brakes, I also wanna remove spokes for a re-vamp, dunno what I'm going to treat them with yet? I must check my OEM tool-kit maybe I have a spoke wrench, what area of Gauteng are you in?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 15, 2012, 10:16:54 pm
Yeah, luckilly I didn't push my baby too hard today. Wildcoast, I'm in Bedfordview, Eastrand. I'm super keen to hook up with a dog with expertise knowledge. I need to look at the carb, but past experience tells me I should think twice before doing it myself. I actually say a post of DR KLR, he's have a technical day or something where you bring your bike (he's also in Gauteng I think) and he think tells you about it, shows you what to do etc. I saw a drz going, so I asked as well, you coming?  Might be fun.

But yah, tell me if you get a spoke wrench. I haven't seen lots but I know you get spoke torque wrenches...want one. DR750 also said he'd help out looking at my DR. Maybe we can all get together..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 15, 2012, 10:17:57 pm
http://www.wilddog.za.net/forum/index.php?topic=88223.0
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 07:44:25 am
I'm going to tackle the carb with the BST bible, seems simple enough, best way to learn I guess....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 16, 2012, 08:17:56 am
Deepbase and Superdave, what carb set-ups are you guys running at this altitude with aftermarket pipes? Any airbox mods? My carb is next on the agenda when my jet kit arrives , wanna try eliminate as much guesswork as possible....

I have the standard carb, but I got the suz dealer to sort out the jetting. I bought the bike from Natal and the bike was running very rich with kak fuel consumption, but fixing the jetting brought it down to a more reasonable 15+km/l (right wrist dependent of course!)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 16, 2012, 09:28:26 am
Gents with my rebuilt BST with bone stock needle and jetting, down here in the Cape, I am getting a consistant 21 - 23 km per litre without riding like a fairy. That's very good consumption for a thumper and best I've had. My KTM640 was around 16-18 , KLR about 19-21 , and my 96 DR never got 23, but see's a regular 21....( not bad for stage 2 mod.)

I think this DR motor's cursed hot cam has a side benefit, at 5000 rpm, which is where you spend most of your time on the open road, it's sitting right bang on peak torque, where the whole dynamic plot comes together.

There is only ONE way to get a carb right, on a dyno with a properly working Lambda sensor. Get the fueling cock-on without guesswork , and for the rest of your bike's days you will enjoy best power and economy. Worth the small $ and a little effort to get this valuable data point. You have to work from the main jet backwards to form a logical chain to set up the carb good and proper.

Naturally before doing ANY of this you first validate your compression, valves, clearances, air filter, have chosen your zorst, plug gap, and all the basics ....

Also another useful observation perhaps ...the stock main of 137.5 is not lean with a Scorch pipe running a stock airbox. Definitely under full load on a cool day at the coast there is no sign of full-throttle roll-back 'perking up'. Maybe Back Then carb bikes were not set quite so radically lean I don't think.

What this implies is you can go leaner on the Reef ???

Geeze carbs these days .... are lean lean lean for emissions, to the point where if the bike isn't blistering hot they cough and splutter.

Even my 94DR had the mixture screw PLUGGED, and when I drilled it out I found the idle screw shut ! But I suspect my bike started life in the USA ???

Getting that idle set up properly was a moment of great joy for me and this bike ! : ) : ) ....no more DYING.

Lastly, most of you know I imagine, bear in mind jet kit numbers ( especially dynojet ) are not the same flow measurement as the Mikuni .... don't get lost !



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 16, 2012, 09:30:52 am
I'm going to tackle the carb with the BST bible, seems simple enough, best way to learn I guess....

Can I join!? I'm in Bedfordview

BTW, soon I'll be changing sprockets and chain, will change rear sprocket to 44 (from 41) to up the revs at low speed in second. Don't know if this has to do with fueling, but my DR is not happy under 3000rpm in second and you many a time do that kind of speed in town. Any comments?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 16, 2012, 09:33:35 am
Gents with my rebuilt BST with bone stock needle and jetting, down here in the Cape, I am getting a consistant 21 - 23 km per litre without riding like a fairy. That's very good consumption for a thumper and best I've had. My KTM640 was around 16-18 , KLR about 19-21 , and my 96 DR never got 23, but see's a regular 21....( not bad for stage 2 mod.)

I think this DR motor's cursed hot cam has a side benefit, at 5000 rpm, which is where you spend most of your time on the open road, it's sitting right bang on peak torque, where the whole dynamic plot comes together.

There is only ONE way to get a carb right, on a dyno with a properly working Lambda sensor. Get the fueling cock-on without guesswork , and for the rest of your bike's days you will enjoy best power and economy. Worth the small $ and a little effort to get this valuable data point. You have to work from the main jet backwards to form a logical chain to set up the carb good and proper.

Naturally before doing ANY of this you first validate your compression, valves, clearances, air filter, have chosen your zorst, plug gap, and all the basics ....

Also another useful observation perhaps ...the stock main of 137.5 is not lean with a Scorch pipe running a stock airbox. Definitely under full load on a cool day at the coast there is no sign of full-throttle roll-back 'perking up'. Maybe Back Then carb bikes were not set quite so radically lean I don't think.

What this implies is you can go leaner on the Reef ???

Geeze carbs these days .... are lean lean lean for emissions, to the point where if the bike isn't blistering hot they cough and splutter.

Even my 94DR had the mixture screw PLUGGED, and when I drilled it out I found the idle screw shut ! But I suspect my bike started life in the USA ???

Getting that idle set up properly was a moment of great joy for me and this bike ! : ) : ) ....no more DYING.

Lastly, most of you know I imagine, bear in mind jet kit numbers ( especially dynojet ) are not the same flow measurement as the Mikuni .... don't get lost !





Wow..that's why I'm not so keen tackling the carb by myself... Veemax, you coming to JHB for a weekend soon?! We need you!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 16, 2012, 09:45:52 am
Heh heh, I learned a lot about carbs the hard way in the last two years .... XT500 x 3 , LS650P Savage , KLR hot mods , KTM BST, DR650SE,  this DR, every single cylinder bike I've touched has been a bloody challenge !

Thumpers are great and simple bikes, but they are super-sensitive to carbs.

My best advice now is start with a slide/slide-guide, and at least a fresh nozzle,  on any old BST.

I have ZERO experience of Pumpers etc , guys swear by them, and I can understand why now !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 09:55:01 am
Volroom I am expecting to get my USA stuff for carb today, I will start playing from then, will strip and clean carb and see whats happening , I'm in Randpark ridge
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 10:04:55 am
My bike was running rich and chomping fuel, prob set up for coast and the dodgy choke cable may be culprits, will wait for new pipe and do valve clearance etc. before trying to dial it in as best I can.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 16, 2012, 11:32:02 am
Volroom I am expecting to get my USA stuff for carb today, I will start playing from then, will strip and clean carb and see whats happening , I'm in Randpark ridge

Saturday maybe? Would be great if we could do it together but if you want to play with it so long that's cool. My bike was also at coastal area, so thinking that it's running to rich also - hint would be that it almost doesn't need choke when starting cold..

PM me the exact address, I'm in Bedfordview. Let me know if you can do Saturday - if possible we'll start early with the BST bible next to us
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 03:22:36 pm
Will do volroom....

In the meantime  :ricky: :ricky:  :blob10: :blob3: :blob3: :blob3: :blob3: :blob5: :blob7:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 03:23:56 pm
Just a mock up for now, bit of fine tuning for a fit needed.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 16, 2012, 04:07:32 pm
SHEEEEET !!!! That looks LEKKER like I wanna EAT IT !!!

OOOOOOOOOOOOOOOOOOOOOOO ......... thats gonna be some special one-off to confuse and amaze that is !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 16, 2012, 04:35:07 pm
Wow, Awesome!!!!!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 04:41:10 pm
Thanks guys, geez I love that tank!!!! It's meant for a 92 , my set up on the tank rubbers differs a bit but will maak n plan!
At least the seat kinda fits and it clears the oil cooler, close to bolt on, now I'm awaiting a nice stainless pipe, should look neat!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 16, 2012, 05:53:47 pm
I should be mobile again with painted rims and spokes by Thursday. The front rim is much better off, as expected, hardly any internal corrosion. BUT !!!! Check those rim joins guys, I see a little split on the weld on mine, I'll go off to Link Engineering with it for a touch-up Ally Nyum Nyum weld and press the owner for coffee, I grew up throwing bricks at him, old neighbourhood fella. If you can't throw bricks at your boyhood friends, who can you throw them at ? < Years later he severed by little finger and two nerves with an axe. Now we drink scotch together >

Point is if Geoff Talbot needs a DR650 for alignment I can pop in there later this week.

I have a small job on my wifes cruiser for him to scope anyway.

That Acerbis tank really does it for me , only a snug fitting G-string bikini could look better.





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 16, 2012, 08:14:27 pm
Naais Wildcoast, love that tank. Gonna be a looker, Saulturday then. PM address pls. Cheers!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 08:17:12 pm
That snug fit will require some heavy drilling, the bike the Acerbis was designed for has a pipe between the two mounting rubbers, mine has a solid steel bar, welded to the flanges.

Veemax if you could use your bike as a jig for Geoffs pipe fabrication I would be eternally muchos bottle of brandy greatfull indeed, he has my original pipe to work off.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 16, 2012, 09:18:22 pm
Looking to fit tyres in the near future: nice 50/50 ones. Had a set of Metzeller Enduro's slip through my hand the other day at almost half price. I do not want to pay almost two grand, had to pay almost two and a half the other day for the GS tyres. So, any bargains out there?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 16, 2012, 09:26:28 pm
I'm also looking at tires in the near future, they must be fuggen tough I been checking the threads its either the kings, heidi or mitas on my shortlist.

Happy with my Heidi rear, have a trailwing up front great for tar Kark offroad though , last trip two up in the sand SWAMBO thought I was screaming with elation as we snaked along, meanwhile it was terror.  ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 17, 2012, 06:40:15 am
Paid R780 for a King 5.1" rear yesterday , same as I put on my 08DR a few weeks back, Le Cap's advice , gonna give 'em a try.

Seem hard as nails , should go some distance, but I'll be cooling off on the knee-down on Franschoek pass now !

Did this for fun this morning with my coffeeeeeeeeeeeeeee .........

Old DR rear wheel bhp 42.6 @ 6700 rpm New DR rear wheel bhp 37.4 @ 6500 rpm, ja hey , the oldtimer makes 14% more rear wheel ooomph. Also 6% more TALKS.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 17, 2012, 06:49:48 am
NMaybe I'll look into Kings rear, front though?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 17, 2012, 07:02:53 am
beedeebeedeebeedeebeedee .....no data.......only know Sirac's and Deathwings for the front , Metzler or Deathwings on a KTM640 and Scorpions, TKC's on KTM950

For thumpers I have no experience other than those two. I kinda like the deathwings 'cause they STICK on tar, and brake in the wet.

I can live with a slippy back end, but not a slippy front end.

I once went hot into a dry blind corner on a TKC front, on Du Toits Kloof pass, at midpoint the road was wet , the front end washed away, long long Afrikaans words came from inside my helmet, and I somehow survived. After that scare I lost all faith in hard knobbies up front, and the advantage on the dirt is minimal to my view anyhow.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 17, 2012, 07:50:33 am
780 is not bad for a rear, front is also a bit of a dilema for me, I want a puncture resistant tire, grip would be nice on tar 2, guess there is no perfect solution, you have one you lose the other......

Anyone using heavy duty tubes, rim locks etc?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 17, 2012, 07:54:18 am
I am using D606s with heavy duty tubes. In my experience that is pretty much puncture proof.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 17, 2012, 08:04:59 am
Mmmmm ja forgot about the Dunlops, what's the pricing like?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 17, 2012, 08:17:55 am
Mmmmm ja forgot about the Dunlops, what's the pricing like?

Runner usually has stock so PM him. The other thing about D606s is they look the freaking BIZNESS. Also excellent offroad, and passable on road.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 17, 2012, 08:25:59 am
I found Bridgestone TW41 / TW42 and Kings KT966 to be the best allrounders & value for money packages on the market for up to 600cc class bikes.

The B. has an edge in the wet (a small one) the K. on dirt especially in Cape winter mud. Both last well and work well and don't cost a fortune.
Everything else I tried (TKC, Sirac, E07, Kenda 270 & 761, Michelin Anakee, Metzeler Tourance & var. Enduro marks, Avon... ) was either scary, expensive, useless in some conditions... About as million combined bike hire fleet kms.

This is if you look for a SAFE ALLROUND tyre. There is no tyre perfect in all conditions. The more dirt bias the faster they will wear or the scarier they will be on tar and vice versa.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 17, 2012, 08:26:49 am
Certainly will look into them once my spoke story is sorted....Thanks for that
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 17, 2012, 08:35:12 am
Thx LeCap, so what about Kings rear and trailwing up front? I had more road orientated tyres on my XL500 and last year doing around a 100km/h I had some interesting experiences...not again, I need grip on gravel/dirt

But...also need tar compliance.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 17, 2012, 09:28:50 am
My TW front says  "41 " , the new King says buggerall on it. How would I know it's a KT 966 ??? ( just being pedantic )

Ja thanks le Cap , am eternally grateful every time you share massively experienced data with us.

I need a front brake disc , am seeing USD 240 - USD260 online shopping , I guess it's time to call Suzuki South and find out their price.

Is that guy who makes disks in CT via Craigs worth the "risk" of a non OEM disk. Disk Risk ? : )

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 17, 2012, 02:16:26 pm
Hey Veemax, sjo I paid R1400 for a rear disk for the GS - motorworks, UK. I've heard of guys having made up discs at engineering shops for cheaper.

What about the Dunlop D606 for rear? Seems it's cheaper than the kings! Looks like a proper knobbly. I need something that'll give me stability on gravel.  R570(rear), R480(front) - if you fit it yourself... that's much cheaper than the kings!!

Think I'm doing that..front as well. I'm not looking for massive traction on tar with my DR, well so on gravel. These prices at Justbiketyre in centurion!! I mean, you can't beat that price and AFAIK, these are good tyres, right?

LeCap, did you try the D606's? what mileage is possible on these?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 17, 2012, 05:16:19 pm
D606s are very good on dirt. Too much tar and it chews them quite quickly, especially at speed. Keep the pressure hard on the tar and it is not so bad. I get 5000km from a rear and 10000 form a front. For my type of usage, the poorer performance on tar is made up by the excellent dirt performance. And yet they look like a propper knobbly!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 17, 2012, 05:26:17 pm
Finally got my tank fitted , geez what a mission..... Certainly not a fits all pre-96 Dr's set up
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 17, 2012, 05:36:43 pm
...but SO WORTH IT !!!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 17, 2012, 07:16:31 pm
Indeed, from close to throwing a match  :blob8: :blob8: to a cold beer and satisfaction that the thing the whole bike was based on, finally fits, shew..... :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 08:38:35 am
Here is my aesthetic anomally DR with rims and spokes put firmly into corrosion history, and sporting fresh King meatball at the back.

It really needs a Karoo backdrop to bring out it's desert character , but as it's about 40 deg there today, um, it'll wait !

Weird colour scheme aside, this bike rides like NEW now. Have only the front disk rotor to renew otherwise there is nothing left needing attention. I'll  do the disk when the pads are shot , could be a while.


(http://i971.photobucket.com/albums/ae199/Veemax/18Jan20121.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/18Jan20122.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 18, 2012, 08:48:19 am
My TW front says  "41 " , the new King says buggerall on it. How would I know it's a KT 966 ??? ( just being pedantic )

Ja thanks le Cap , am eternally grateful every time you share massively experienced data with us.

I need a front brake disc , am seeing USD 240 - USD260 online shopping , I guess it's time to call Suzuki South and find out their price.

Is that guy who makes disks in CT via Craigs worth the "risk" of a non OEM disk. Disk Risk ? : )



The KT966 tyre thread pattern is printed onto my T-shirts where it says "Suzuki".

I'd buy a disk from a reputable manufacturer. I had disks made locally (Fidel) in the past, the ones I got were fine but they sometimes had problems with the steel & heat treatment.

Procycle has generic disks for teh SE for US$ 110. Sure you can find something for the old DR too?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 09:07:25 am
You confirm my deep skeptisim regarding materials of dodgy disks .... thanks !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 18, 2012, 12:07:11 pm
Thx DB9  - LeCap, have you tested D606's before? 5000km for rear is acceptable to me. How much would you get on the Kings?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 01:03:12 pm
Just a thought ....look at the APPLIED tyre cost expressed as ZAR/km.........goedkoop is often duurkoop ! This is why I'm taking Le Caps' advice.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 18, 2012, 02:02:53 pm
Just a thought ....look at the APPLIED tyre cost expressed as ZAR/km.........goedkoop is often duurkoop ! This is why I'm taking Le Caps' advice.
Agree....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 18, 2012, 02:06:00 pm
(http://www.wilddog.za.net/forum/index.php?action=dlattach;topic=79505.0;attach=150306;image)

D606  :mwink:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 03:02:12 pm
That does look the businez!  :thumleft:

Well I have the BST on the work bench, I'm delving into new territory wish me luck!

The Kit I have suggests 155-160 main jet, their needle, clip 4th groove from the top for a more free flowing pipe.
Im wondering should I just do that and fine tune from there?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 03:17:45 pm
Definitely start point should be their recommendation , er on lean side for altitude ....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 03:27:07 pm
Never underestimate the power of Chaos. I had to abandon my DR under a tree this morning, and take a long walk in 35 Deg heat.

Sudden Battery Death Syndrome. It still measures 12.65 Volts, but I walked out the shop and it said Clack Clack , Goodnight Nurse.

A Fresh battery ( http://www.motobatt.com/ ) , and it's alive again. WHERE'S MY KICKSTART ?????

DB9 , gimmee your Dakar !!!

Very glad it died close to home. Note to self: When rebuilding a used Adventure bike with e-Start only, buy a new battery so you KNOW what you have on board !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 18, 2012, 03:37:06 pm
I love my kickstart! Its nice the when you switch on the bike and the battery is dead, it makes no difference, you just kick it into life and off your go....... :ricky:

Is it not possible to retrofit a kick start?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 03:39:10 pm
I doubt it, maybe, but the parts bill would kill the idea ! IF you could find them !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 18, 2012, 03:40:35 pm
You have the hole in the crank case:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 03:44:47 pm
Ja, tantalising isn't it ! I should do the exercise and see if I could not order the parts in theory. Not really in the mood to tear down my nice new motor. I didn't even bother to try to bump start it,  the compression right now is at a peak.

the ONE weakness of this bike pops up in it's first few weeks back to life !!!

I say that is LUCKY !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 18, 2012, 04:04:14 pm
Jumpstart in 2nd normally works, ask some oke to give you a push
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 04:33:17 pm
Jumpstart with a piece of wire on automatic de-comp lever LOL
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 04:58:59 pm
Right..... started stripping my carb, noticed the slide is grooved, do I have problems here?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 05:02:00 pm
The needle as it was when I removed it, should the part marked with the red arrow not be where the yellow arrow is?
Clip 3rd groove from top, the spacer that is advised to be removed is chipped, Moose racing needle (bottom)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 05:56:05 pm
Thats not a chip, look again, it seats into a corresponding impression inside the slide ! If you rotate it you will feel it slot into place.

Anyway, it's history .... they say leave it out ! ??

Ok, lets go to the slide.

Take off the main jet and remove the nozzle out through the top of the carb, then pull the whole slide guide out and look for the O-ring under neath.

Get the slide and slide guide together , really look at it for wear, at the bottom edges ....

Lets see how that looks, you have to build from there.

If it's really hammered, your new fancy dynojet needle is going to be worn and useless in the next 8000km ....

This is where you have to face facts.

Lets first ID your carb, outside on the left should be a number. Mine said 12EF // 411 , yours will be more modern I think, as already your needle has slots, mine didn't .

Whats the number on the needle that came out ? 6F10 or later ?

Get the nozzle out ! 691- y2 or later ?

Take your time, open a beer. ZENNNNNN !!!!!!!! This is the part you DO NOT rush !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 06:00:14 pm
Wait!!!! It get's better, no needle valve in carb?????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 06:02:55 pm
18DS K341
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 06:03:55 pm
Needle, H9
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 06:04:00 pm
And while you are disassembling, let's get those minor jets out. Pilot air, is it 1.3 ?? Pilot jet, is it 52.5 ? The throttle butterfly, is it 110 ?

Is the idle screw plugged or accessible ?

If plugged, we're gonna UN plug it, give you back Control !!! Look for a wee brass insert with a really tiny hole dead centre ...if you see the idle adjustment needle instead you see a screwdriver slot...if so, measure the turns to a light seating IN, note that down, then unscrew it and get in on the bench. Look at the O-ring ! Is it OK ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 18, 2012, 06:11:40 pm
Jumpstart with a piece of wire on automatic de-comp lever LOL

Oops..mean running start
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 06:19:55 pm
Run and Jump Start hahahahahhaa !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 06:22:17 pm
Wildcoast has a very modern carb .....dude, check how many holes in the slide, One or Two ???

Even my KTM manual doesn't know an 18-series .....

Anyway, don't panic, give us your engine number and frame number to look at. PM me if uncomfortable.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 06:27:29 pm
Okay, will do just a sec, main jet was a 140, removed that and pushed down, nothing budged, so left it all with wd40 soaking overnight

3 holes in slide one large in centre smaller ones either side
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 06:30:41 pm
OK, two "lift holes" in slide ....  period correct slide ....the post 96 has a single lift hole.

That nozzle might need a little gentle gentle gentle tap with a pursuading tool, add some warmth too.

It's meant to be a snug fit but it should NOT require donnering ! : )

Is your idle screw plugged you think ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 06:34:53 pm
PM sent.....I think
Fuel mixture screw not plugged
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 07:32:16 pm
From what I can gather your bike is a 1993 DR650RSE with a full-power engine , definitely year code "P" for 1993

The "A" in SP43A means it's for the "world " market and not restricted. Yay.

Your motor code 'P405'  predates mine which is P407, and mine rolled off the plant in 1994 for sure.

Your engine is SP43 and mine is SP45 which also confirms the period as 1993. Looks like a 'matching numbers' bike.

At least we now know which blerrie manual and fiche to look in !!!

Hope this helps ? It's confusing, whats posted and what you can learn ... it's long road to drill down.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 07:36:35 pm
Thank you , where do you find this info?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 07:41:05 pm
I forgot ! I scribbled a whole page or two searching the web last year ,  so I have a A4 full of pencil scrawls with notes explaining some of the notations , in the file of this bike.

It took a while and got very confusing.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 07:58:27 pm
Sharing is caring  :biggrin: How about posting some of those resource sites?

Seems my bike was a french market bike, can find some info but all in french


Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 18, 2012, 09:14:41 pm
I don't know those sites any more man, maybe Thumpertalk , AdvRider, Suzukicycles.org , anything that Google and a bit of patience will yield, then there is also the workshop manuals , suppliers like DennisKirk, Ron Ayers, Alphasports, Bikebandit, CMS, shit man, you're just as likely to find it as I am, if not more so. My idea of Tech savvy is to use Dogpile instead of Google ! This laptop is Celeron powered dude !

You want a deep web search, you need to be born in 2000 not 1962 , to know that stuff !

Did you check your float height by the way, itching to know what it was .... there be demons I tell yah !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 18, 2012, 09:28:12 pm
Have left carb for now, still trying to find if I have a freak variant of a BST40 and research the bloody thing online, looks like a BST40 but certainly different

After browsing DRRIDERS forum I came across a similar incident that I had, no needle valve in a post 96's carb.
Some BST's have the needle valve mounted in the float, no reason to panic....-shew-
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 19, 2012, 08:03:38 am
I've got a 93 DR, so possibly same carb as yours. Just want to inspect the condition of needle, slide and what not and clean.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 08:26:47 am
Well my carb is fucked!!!!! In trying to get the slide guide out the needle jet, that was tacked to the guide, has broken free and is now wedged in its tunnel, so looks like I need a new carb, cause i'll prob have to drill it out!!!!  >:(

Had to resort to knocking needle jet out with a punch, think I need a new carb, anyone????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 19, 2012, 08:38:26 am
i have a carb...
it was from my DR650SE,  replaced with Mikuni TM40.
make me an offer...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 08:41:30 am
LOL i just PMed you, I dunno what these things are worth?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 19, 2012, 08:42:51 am
phone the stealer,  and ask how much new.
you can have mine for a 3rd of the price.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 19, 2012, 08:59:49 am
Tough luck WC, shit happens huh. Sorry man. Search earlier in this thread someone offered me a carb and we exchanged dealer price info, somewhere in the  R3k region ? I'd take that deal in a flash.

I searched the web last night for any model data on the "Slingshot" carb. The only thing I learned was that those string things hot Brazilian babes wear are called Slingshot's too.

Tell me, if your bike has French origins , does it have a metric dash ? I wouldn't mind a metric oldtimer dash , maybe I could offset that carb cost a little ? Assume you are going Vapour , right ?



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 09:08:23 am
Okay new carb sorted from THEOTHERGUY, thanks for the response, would rather have something thats more stock and newer anyway, easier to get parts etc.

Right Veemax, that dash is in KM, but shaped for a fairing, I'll post pics in about 5min
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 09:16:24 am
There we go....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 09:17:52 am
And...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 09:18:53 am
The back....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 19, 2012, 09:27:27 am
Let me ponder that, thanks, useful bracket pic , really shows what I need to make a decision.

Ask TOG for the carb ID on the left side of the body , lets see what it is !??

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 09:31:29 am
I'll have the carb tonight, will let you know, should bolt straight on, I have all the manifolds etc, and lots of spare BST parts  ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 19, 2012, 09:54:33 am
I'll have the carb tonight...

quick service...
nothing like the WD forum.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 10:01:52 am
That's no lie, beats fleabay hands down  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 19, 2012, 01:47:43 pm
So your getting new carb...wow. BST-40?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 19, 2012, 02:16:36 pm
So your getting new carb...wow. BST-40?

yup BST-40,
he's buying it from me.
i've got another BST-40 (had 2), 
interested in it???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 19, 2012, 02:40:24 pm
Off Topic during Carb Week, but here goes!

My DR let me down twice in 24 hrs by refusing to swing. A co-ord fella can, in fact, bump start this DR, right first time this morning but on a downhill, lucky for me, I stopped on a hill to check, and it proved genius, it not wek !!! clack clack clack vokkol. Oops.

So I learned three things today.

(1) You can strip these lekker old school starter solenoids, clean it up, clean the contacts, grease up the plunger and put it back together . HELL YEAH. Try THAT on your sealed unit R1200GS Can Bus Uber Teknik huh !!!! 18 years later and good as new.

(2) Do not underestimate the importance a nice clean tight high-current connection to the starter, the root cause of the No-Go.

(3) No other mans work will come anywhere close to the detail, caring, and precision of your OWN. Trust No One.

Ok, Murphy, what ELSE have you in store for me, because I cannot for the life of me imagine anything else left on this bike besides the bowels of the gearbox, that I have not thoroughly attended to...

I think a rip around Cape Point ...er.....sorry Vaalies........ >:D >:D





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 02:45:50 pm
I have been there , flat battery , run start with a piece of wire on de-comp, my de comp only works with clutch in I think, was locking wheel in 3rd

Will certainly look at my solenoids now that you mentioned it Veemax.

Well airbox prepped for new carb, brand new nicely oily filter inside sealed with grease
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 19, 2012, 02:57:11 pm
So your getting new carb...wow. BST-40?

yup BST-40,
he's buying it from me.
i've got another BST-40 (had 2), 
interested in it???

maybe......I'll be opening mine up on Saturday with wildcoast...wonder if I should...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 03:10:38 pm
Bring a big hammer  :imaposer:

It's pretty basic stuff actually , mine was rusted vas inside and I was a bit heavy handed, if you have the same problem just dont moer it  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 19, 2012, 04:59:42 pm
gooi some pics there wild coast of this new carb and old - they are exactly the same?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 19, 2012, 05:05:43 pm
Sorry dudes. You know when you go for a ride, and you, and the bike and such .... all comes together , and you go YeeHah in your helmet ?

Well, for motivational purposes ( bullshit , it's a brag pic ) I took this for you about an hour ago ...

(http://i971.photobucket.com/albums/ae199/Veemax/19Jan12.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 05:09:30 pm
Awesome!!!!!

Can't wait for my bike to start posing for pics.....

Will do Volroom, must get new carb first.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 19, 2012, 05:32:43 pm
Sorry dudes. You know when you go for a ride, and you, and the bike and such .... all comes together , and you go YeeHah in your helmet ?

Well, for motivational purposes ( bullshit , it's a brag pic ) I took this for you about an hour ago ...

(http://i971.photobucket.com/albums/ae199/Veemax/19Jan12.jpg)

Nee man John....nee man...that does something to this cape heart of mine. Won't stay too long here in the vaal district..couple of years
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 05:37:52 pm
A view from the sea side.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 19, 2012, 08:33:55 pm
okay, new carb says, 32E3 H891

Volroom , almost identical to old carb, a few subtle external differences , prettier though, will investigate innards tomorrow sans the influence of beer
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 19, 2012, 09:43:49 pm
okay, new carb says, 32E3 H891

Volroom , almost identical to old carb, a few subtle external differences , prettier though, will investigate innards tomorrow sans the influence of beer
I'm sure between the 3 carb's we'd be able to make something of it
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 20, 2012, 09:09:26 am
okay, new carb says, 32E3 H891

Volroom , almost identical to old carb, a few subtle external differences , prettier though, will investigate innards tomorrow sans the influence of beer

OK, the modern DR manual says this carb 32E3 is for the Sweden/German/Australian DR650SE market

Data as follows

Main 140 , 6F19 needle on 3rd clip , Y5 , throttle valve # 95 , Pilot 42.5 , Starter Jet 40 , idle screw 1 turn out

You should see a single lift hole on the slide , unlike the old DR , Derek Capito of Motolab says this is a design change to reduce flutter and slide wear, unless you are building a stunt bike, my vote syas leave it.

On the throttle body the DR has a lever on the right that closes a microswitch at full wide open. This is intended to que the CDI to retard the ignition during neck-ringing of the new DR. I cut mine off and tossed the wire away because I am not a retard that holds a thumper at full revs all day.

Float height is the same with this carb, 14.7mm +/- 1mm.

This is about all I have to offer of possible assistance, good luck guys.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 20, 2012, 09:12:17 am
Morning all! Right , got my new carb from TOG last night, shew he has some lovely machines....
Stripped the carb, stock off a post 96 DR prob set up for this altitude from the dealer
It was running the same main jet as mine (140) diff idle jet and needle settings, both floats set at top clip, the innards of both carbs are identical, pic explains idle jet, needle settings etc, as can be seen my carb had o-rings missing, don't know if this is standard or lost by PO or his mechanic, maybe this explains my terrible fuel consumption.

So now it's clean and re-assemble with new parts, any suggestions on new settings , stock filter, no snorkle and aftermarket pipe?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 20, 2012, 09:16:06 am
Good timing, thanks Veemax, the slide has been drilled already I'm afraid....
Now with two springs I can cut one and see what happens  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 20, 2012, 09:21:18 am
How is the nozzle opening for oval , and the slide for wear ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 20, 2012, 09:21:51 am
watching with interest.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 20, 2012, 09:30:17 am
A few minor furrows on the slide, alot better than the old one, besides that it's almost brand spanking new  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 20, 2012, 09:37:01 am
TOG , really like your bike collection : ) , how many km had this carb on when you displaced it with a pumper ? My 08DR has only 13 000km on it , I was wondering what life one can get out of a BST before it becomes MOEG ?

I had a K&N on my new DR , some inlet mods , header weld grind , main jet a 150. After researching how much shit goes right through a K&N I tossed it out and put the OEM foam back ! I could swear there is little difference. No science, no dyno, sorry.

Ja, anyone wanna K&N ? You can HAVE it.

Don't trust a filter you can SEE thru man !

But the extra airbox hole, and screen removal, and zorst and jet and needle clip vroetel, really does wake up the new DR.

I am sitting on the fence wondering if my hole saw and my old DR airbox should not become better aquanted : ) , however, it's quite nice for a change to have a factory bike. All my bikes are Vroeteled . My best experience was getting +23 bhp from a stock Bandit without touching the motor, that was fun !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 20, 2012, 09:40:05 am
I was actually thinking of drilling a few holes extra in the airbox , or making another beeeeeeg hole and fitting two snorkles, problem is Suzuki does not make snorkles anymore  >:(
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 20, 2012, 09:49:28 am
i checked on the Ganjamobile thread,  and see i replace the carb on 3 june 2010.
had the bike for 1 year at that stage.   bike is on 46000km at the moment.
i'd guess about 15-20K km on the carb at that stage - not really sure though...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 20, 2012, 09:49:52 am
I was actually thinking of drilling a few holes extra in the airbox , or making another beeeeeeg hole and fitting two snorkles, problem is Suzuki does not make snorkles anymore  >:(

i think i've got another snorkel...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 20, 2012, 09:56:33 am
I wonder if the post96 will fit the hole for the pre-96? My old snorkle is missing so I'm after 2 of them, More air and can still Fjord , that's my reasoning anyway.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 07:40:16 am
Good morning all, spent Saturday fiddling with Volroom's carb, certainly learned alot about the BST! Think he needs to fine tune a bit (lovely bike for what he paid for it WOW!)

Was looking at the pre-96 DR thread on Advrider and I noticed that they mentioned clutch slipping in 4th and 5th gear seems to be inherent in these older bikes, can anyone comment on that , what will the fix be? (my bike does this at the top of the rev range in higher gears)

Also noticed on e-bay the aftermarket fork springs advertised for the older DR's is the same as the KLR 2008 and up?

Veemax did you take any pics of your fix of the non-starting issue? Would like to prevent before I need to roadside cure  ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 23, 2012, 08:01:45 am
Good morning all, spent Saturday fiddling with Volroom's carb, certainly learned alot about the BST! Think he needs to fine tune a bit (lovely bike for what he paid for it WOW!)

Was looking at the pre-96 DR thread on Advrider and I noticed that they mentioned clutch slipping in 4th and 5th gear seems to be inherent in these older bikes, can anyone comment on that , what will the fix be? (my bike does this at the top of the rev range in higher gears)

Also noticed on e-bay the aftermarket fork springs advertised for the older DR's is the same as the KLR 2008 and up?

Veemax did you take any pics of your fix of the non-starting issue? Would like to prevent before I need to roadside cure  ;D

My clutch doesn't slip there? I could be a worn clutch basket? The clutch plates wear notches into the clutch basket and don't disengage properly.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 08:09:00 am
So my best bet is to pull out the clutch and look see? Oh gonnas this is going to be interesting to say the least.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 23, 2012, 08:16:20 am
My mate who turned 50 said he's found my cell phone lurking in the side pocket of the wine carrier I left at his place , battery now flat, and his son says it bleeped a few times before it died ... he did say there are messages from "Cxxx - DR "

Ooops.

I'd better fetch it today !

Glad to see there was a lot of action on the weekend, anyway, WD migration looks good and we are Bahhhhck !!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 08:20:32 am
Yeah Volroom called you to see what carb set you had, I replaced his jets , main and Idle to stock and gave him an adjustable needle , seems his bike was restricted
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 23, 2012, 08:28:59 am
Let me play catch-up ....

Starting issue was a loose cable joint to the starter motor, 1/6th turn with 10mm spanner ....but then I cleaned the contacts and did it proper.

Clutch slip , I had clutch slip too, refer/search back to proper assembly of those steel rings , if not that then plates are either worn or contaminated with slip additive from using the wrong oil. I put in new plates and my clutch is settling in nicely from being obviously a little grabbly at first.

My Master Mechanic friends says those notches one often sees in the basket thrust edges, are not known to impact clutch slipping ....

And lastly, the old needle does not have multiple clip positions but some washers from Builders Whorehouse provide a neat solution to tweaking ...upwards at any rate.

Did you guys discover any badly out float heights in your work on the weekend ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 08:34:08 am
Floats looked good, his pipe leaks at join between header and tail can, we put in new plugs , drilled out plug for mixture screw put needle on 4th clip, got the bike idling smoothly, I rode it and it seemed pretty good, only up to 4th (ran out of road) Maybe he should do valves, timing chain and fix pipe before fine tuning the carb?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 23, 2012, 09:10:19 am
DEFINITELY time to do tappets , you need to know those are right , as a top top priority ...always the Big Unknown when you buy a used bike !

Imagine a riding valve or clearance so large the cam timing is all bent out of shape ? You have to start here.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 09:19:44 am
Wish me luck today, thinking of doing valves, balancer/timing chain (if thats the correct term) and pulling out the clutch for a look see, what did your new clutch set you back? what did you replace? any special tools needed? Will I need new gaskets/seals before I start?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 09:24:15 am
Hey guys, yeah -we had interesting weekend. I want to do the tappets - is there a doc that describes how you do it somewhere? I've done it before on the XL, but LOL I set the valves when the piston on it's way down for intake stroke, not power stroke if you can understand that.... I just want to know how I can be sure that the piston position is absolutely right, and then the valve clearances pls

I'm going to sort out the exaust before I start with the carb. When I do start (if needed), I need a list of mods to the carb that I should do - like: "change this first, if that doesn't work - change this, if that doesn't work change that"

When I've got at the moment is the following:
Good low down torque but bad top end torque/power

What did we do?
Changed the idling jet from 52.5 to 42.5

Now on this.... some oke told me that typically these carb's are set up for sea level - so running a bit rich in the highlands (because there is less oxygen up here than down there necessitating less fuel). He said exactly that: maybe the low down grunt is caused by lessening the fuel in the low revs - changing idling jet from 52.5 - 42.5

I changed the main jet from 137.5 to 140
We made the needle (clip settings) more rich

AND there is less power at top.

My question: can these results be due to enriching the mixture too much at higher revs - flooding the carb, less power?

BTW, thx Wildcoast for helping out and giving me the modifiable needle and other idling jet! appreciate.  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 09:25:03 am
Wish me luck today, thinking of doing valves, balancer/timing chain (if thats the correct term) and pulling out the clutch for a look see, what did your new clutch set you back? what did you replace? any special tools needed? Will I need new gaskets/seals before I start?

WC, do you have your pipe then?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 23, 2012, 09:39:18 am
Sorry I can't give detailed breakdown. What happened was I did one long trip to validate the motor, and all seemed fine, then suddenly it turned oilburner with one tank of gas. ( I had the same experience on my KLR , instant overnight oh-shit-something-is-very-wrong-in-the-bore-now-suddenly ! )

Both scenarios direct relate to engine damage consequential to either air filter falling OFF unnoticed ( eeek ) on a dirt ride , or the tell-tale of a home-made botch job airfilter !

Anyway, as soon as the mill chewed 500ml/1000km I committed to a total top-end rebuild , so clutch, timing chain, bore, valves, all the polymer seals, etc etc, were done in one big project , which I have to admit, I wimped out on and gave to the Awesome Mr Claus Tyrzyk in Killarney Gardens to take care of. The final bill was in the order of R8000.

The parts we tried to source directly, but just like the rebuild on my wifes 650 Savage , it turned out that Suzuki's prices were not bad ( remember, I am a recovering BMW / KTM owner ! )

We placed a consolidated order on Suzuki SA and the parts arrived from Japan in about 2 weeks, good service for a bike nearly 20 I'd say.

You have SUCH a good deal on the purchase price of that bike , that you must be prepared to spend a few more grand to make it LEKKER !!!

It took some willpower not to intercept that scoot and pull it out from under you for myself , when I went to see it !

Clutch plates are a little over R100 each I think, the steel ones are around R90 if you have any warped ones.

The only rip-off parts were valve stem seals , but then a huge markup on a small item can go unnoticed and not worth the sweat.

Cam chain is R400-R450 but your chain should be good, balancer chains don't really take strain and last the distance.

I'd do the valves and balancer chain and clutch , get the carb close, and take it for a serious ride to confirm the bore is in spec , then build a bike around a good engine.

Whats the condition of the air filter ?

 
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 23, 2012, 09:48:43 am
Rule # 1

The Japs are clever people

Set the bike up standard as a starting point , check everything is working properly , get it to start, run. idle ....

Tweak for those last horses and invest time on optimising once you confirm the engine is a goodie, which we hope for !

Optimum Stochiometric Ratio will give best power, going rich on the main at this point is not what I'd do, given your altitude.

Even at sea level I don't find the 137.5 lean with open pipe ....  but I do have stock airbox+snorkle ....

Check the valves dude, and when you have a spanner on the crank, feel that compression !!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 23, 2012, 10:08:36 am
Clutch slip , I had clutch slip too, refer/search back to proper assembly of those steel rings , if not that then plates are either worn or contaminated with slip additive from using the wrong oil. I put in new plates and my clutch is settling in nicely from being obviously a little grabbly at first.

My Master Mechanic friends says those notches one often sees in the basket thrust edges, are not known to impact clutch slipping ....

Note that bad friction discs in your clutch don't necessarily measure below spec. Overheating the clutch lowers the friction coefficient of the discs an effect similar to glazing of brake pads. If the clutch slips on hard acceletation at higher rpm in top gear replace the friction discs.

Thrust marks in the clutch basket and hub spline surfaces causes jerky and difficult to control engagement of the clutch. The worse the marks the more difficult it gets to slip the clutch sensibly. It might also cause the clutch to drag when disengaged and make gearshifts noisy and downshifts sticky and neutral difficult to find although this is typically caused by corroded or warped steel discs.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 10:31:02 am
Volroom DB9 has a link to the service manual on this thread, downloaded it quick quick this morning, explains balance chain and valve clearance very well.

Okay, I'll get some pricing on the clutch story, seals etc, my airfilter is brand new, bike has compression, does not use a drop of oil, think Volroom's bikes motor is still strong as well, when I rode it it pulled nicely, maybe needs a few tweaks for the mid range but I thought it pulled well.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 04:49:35 pm
Rule # 1

The Japs are clever people

Set the bike up standard as a starting point , check everything is working properly , get it to start, run. idle ....

Tweak for those last horses and invest time on optimising once you confirm the engine is a goodie, which we hope for !

Optimum Stochiometric Ratio will give best power, going rich on the main at this point is not what I'd do, given your altitude.

Even at sea level I don't find the 137.5 lean with open pipe ....  but I do have stock airbox+snorkle ....

Check the valves dude, and when you have a spanner on the crank, feel that compression !!!

Ok, after the exhaust leak is sorted I'll remove the snorkel just to see whether the end torque increases. If it does - then I know that it is running too rich at high revs possibly due to bigger main jet and richer setting on needle.

In the end it might take a while, hey? Love the fact that I'm learning though - never saw chance for a carb before.
What mods did you make to your BST-40 exactly Veemax? And LeCap - need some comment on the Dunlop D606's pls.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 04:52:03 pm
Volroom DB9 has a link to the service manual on this thread, downloaded it quick quick this morning, explains balance chain and valve clearance very well.

Okay, I'll get some pricing on the clutch story, seals etc, my airfilter is brand new, bike has compression, does not use a drop of oil, think Volroom's bikes motor is still strong as well, when I rode it it pulled nicely, maybe needs a few tweaks for the mid range but I thought it pulled well.



Thx WC, will pm DB9. She pulls OKish...but honestly  - in top gear, slight very slight hilll at around 110-120km/h - you can open throttle wide and absolutely nothing happens. Veemax says with the pre-96 (hot cam) this should not be so

BTW at around 120 I'm doing just over 5000RPM
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 23, 2012, 05:04:53 pm
Here's the link again for the service manual. I'm going to put it on the 1st post on this thread as well :  http://www.dreamlodge.co.za/1990-1995_DR650_Service_Manual.pdf
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 05:35:57 pm
Got the service manual, thx DP9. see the API rating on oil used should be SE or SF...that is supposedly low quality oil. the s is for spark ignition (c would be form compression ignition - diesel), the second letter shows quality of oil, the further down the alphabet the better quality oil - that's what I understand. So...do you use SE SF oil?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 05:43:16 pm
Been running around a bit today doing chores, collecting scrap steel and ordering parts etc. In order not to waste a day totally I slapped a pooratech rear brake master cylinder guard together from some old scrap angle.

Volroom did you watch that movie yet?  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 05:50:19 pm
Been running around a bit today doing chores, collecting scrap steel and ordering parts etc. In order not to waste a day totally I slapped a pooratech rear brake master cylinder guard together from some old scrap angle.

Volroom did you watch that movie yet?  :ricky:


Will do, will do.. sent you a pm. Teaching keeps me buisy...or is that WD forum keep me buisy..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 05:58:19 pm
Now the service manual says I put in the wrong plugs.. does anyone have a code (NGK) for the plugs that should be used? think those i've got in is DEA 8
Manual says last nr should be 9..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 06:06:45 pm
You mean I burned my hands playing with the mixture screw to set it up for the wrong blerrie plugs?  :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 23, 2012, 06:13:00 pm
You mean I burned my hands playing with the mixture screw to set it up for the wrong blerrie plugs?  :imaposer:

frieken seems like it...sorry, but if possible I'll just keep en in..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2012, 07:13:34 pm
Any advise on what temperatures a CDI unit generates? I need to move mine, was thinking under my seat on the tailpiece (resting on plastic) is this a good idea?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 24, 2012, 09:11:03 am
CDI does not get significantly warm and also does not like large amounts of heat. Put anywhere you want and as far away from exhaust header and silencer as possible.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 24, 2012, 10:05:21 am
Thanks Le Cap
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 24, 2012, 10:31:14 am

Got the service manual, thx DP9. see the API rating on oil used should be SE or SF...that is supposedly low quality oil. the s is for spark ignition (c would be form compression ignition - diesel), the second letter shows quality of oil, the further down the alphabet the better quality oil - that's what I understand. So...do you use SE SF oil?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 24, 2012, 10:32:13 am

Now the service manual says I put in the wrong plugs.. does anyone have a code (NGK) for the plugs that should be used? think those i've got in is DEA 8
Manual says last nr should be 9..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 24, 2012, 04:29:57 pm

Now the service manual says I put in the wrong plugs.. does anyone have a code (NGK) for the plugs that should be used? think those i've got in is DEA 8
Manual says last nr should be 9..


My manual ( 1992 publishing ) says

NGK DP8EA9 , hotter plug for Canadian cold ???
NGK DP9EA9 = default

Gap 0.8-0.9



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 25, 2012, 08:52:03 am

Got the service manual, thx DP9. see the API rating on oil used should be SE or SF...that is supposedly low quality oil. the s is for spark ignition (c would be form compression ignition - diesel), the second letter shows quality of oil, the further down the alphabet the better quality oil - that's what I understand. So...do you use SE SF oil?


API SE and SF have been superseded decades  ago.

Current and valid service classes are SJ, SL and SM with the first two principially being suitable for bike engines.

You might find some El Cheapo oils which are labeled API service class SG too but that's obsolete too.

JASO SM has basically replaced all earlier and current API service classes and at least the Japanese manufacturers and KTM recommend to run their bikes on JASO MA spec oil regardless what year model.

And use 10W40 or 10W50.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 25, 2012, 09:53:25 am
Thx LeCap, the reason why 20W50 should not be used is because it takes a while for these engines to warm up, right? Using 20W50 does not give sufficient lubrication at low temperatures.

D606 Comment Le Cap?
Is the Kings rear that Veemax put on a 6 ply tyre?

Veemax, thx. It basically means i've got the wrong plugs in. Mine ends with 8 - not 9, LeCap - what difference is there then? should I change plugs again?

Thx

BTW WC, I checked mondo Enduro last night...awesome!! Those guys were HARDCORE..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 25, 2012, 09:58:27 am
I use Magnatec 10W40 in all my Suzis, seems to to the trick.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 25, 2012, 01:06:26 pm
Here in CT Craig's buy's in 200L barrels of Putoline 10W50 , you pitch up with your own can and buy 5L for R200 I think. Anyway, it makes a lot of sense so I've shifted in that direction now.

I've never managed to wear out a bike so all the oil hype to me is not worthy of too much consideration ! Rather be kind to you engine when it's cold, attend to your airfilter, relax, put in a reasonable quality oil as per spec, and ride the bloody thing !  :ricky:

Mostly ALL the engine wear happens from cold, attend to that,  and your bike will thank you.

It's all to do with Fluid Wedge but then we need to dust off the textbooks. Um. No.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 25, 2012, 01:19:00 pm
I use Magnatec 10W40 in all my Suzis, seems to to the trick.

that might be an idea....thx!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 25, 2012, 03:11:10 pm
The plugs I put in says 2120 D8EA
The plug that I got from suzuki says: DPR8EA9

i think that these plugs might be interchangeable: 8 followed by EA for both (both NGK)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 25, 2012, 08:08:13 pm
QUESTION: How do I know whether the carb is set too rich or lean? I need to know, because if it is lean I might burn valves. I have no idea how it is set at the moment, but something is not lekka. Today it felt asif petrol was finished, but it wasn't. I don't know. Please give me same practical advice on how to figure out whether to problem is too much petrol or too little. Pretty pls

Veemax, do you know what jets you are running currently? stock needle?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 26, 2012, 11:01:08 am
Here in CT Craig's buy's in 200L barrels of Putoline 10W50 , you pitch up with your own can and buy 5L for R200 I think. Anyway, it makes a lot of sense so I've shifted in that direction now.

At that price it's most likely 20W50.
10W50 spec is not achievable with cheaper semi synthetic base stock unless you use tons of viscosity modifiers (which you don't want to)
Means even itf it is 10W50 I would think twice before buying it. There is a reason why a good JASO MA SAE10W40 retails for around R70 and 10W50 for R100 or more.

D8EA and DPR8EA9 are not identical and not interchangeable either.

I do not recommend experimenting with non standard heat value plugs and even less with non standard type plug unless it's either a ground electrode variant of the same type plug (Example: CR10E is the single ground electrode type in DR650SE. You could substitute a CR10EK twin ground electrode variant which in theory should give you a longer plug service life. Since it's more expensive too you can just as well forget about it) or it's a centre electrode variant plug of the same type (Iridium plug for example).
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 26, 2012, 11:27:17 am
QUESTION: How do I know whether the carb is set too rich or lean? I need to know, because if it is lean I might burn valves. I have no idea how it is set at the moment, but something is not lekka. Today it felt asif petrol was finished, but it wasn't. I don't know. Please give me same practical advice on how to figure out whether to problem is too much petrol or too little. Pretty pls

Veemax, do you know what jets you are running currently? stock needle?

Pull the carb and put her back to how she was
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: grego on January 26, 2012, 11:54:50 am
Here in CT Craig's buy's in 200L barrels of Putoline 10W50 , you pitch up with your own can and buy 5L for R200 I think. Anyway, it makes a lot of sense so I've shifted in that direction now.

At that price it's most likely 20W50.
10W50 spec is not achievable with cheaper semi synthetic base stock unless you use tons of viscosity modifiers (which you don't want to)
Means even itf it is 10W50 I would think twice before buying it. There is a reason why a good JASO MA SAE10W40 retails for around R70 and 10W50 for R100 or more.
makro sells castrol power1, fully synthetic, JASO MA SAE10W50... R69.95 a litre  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 26, 2012, 01:02:56 pm
When doing valve clearance, how do you work out wich one is the compression stroke?  ???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 27, 2012, 08:18:28 am
Got the dash story sorted out finally....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 27, 2012, 08:27:56 am
lekker unit,  the vapor.
had one on my klr.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 27, 2012, 08:34:45 am
Now to figure out where all the wires go  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on January 27, 2012, 08:35:43 am
Now to figure out where all the wires go  :biggrin:

it's actually pretty simple,  they're all labelled.
if you get lost,  Groenie knows - he did both mine and his.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 27, 2012, 10:59:05 am
When doing valve clearance, how do you work out wich one is the compression stroke?  ???

Two ways:

Its the TDC after the intake valve has closed. You need to know which way the engine turns.

It's the TDC where you do have valve clearances. The engine needs to be in running condition. Might not work after a rebuild or on a piece of scrap.

Here in CT Craig's buy's in 200L barrels of Putoline 10W50 , you pitch up with your own can and buy 5L for R200 I think. Anyway, it makes a lot of sense so I've shifted in that direction now.

At that price it's most likely 20W50.
10W50 spec is not achievable with cheaper semi synthetic base stock unless you use tons of viscosity modifiers (which you don't want to)
Means even itf it is 10W50 I would think twice before buying it. There is a reason why a good JASO MA SAE10W40 retails for around R70 and 10W50 for R100 or more.
makro sells castrol power1, fully synthetic, JASO MA SAE10W50... R69.95 a litre  :thumleft:

If you vcan get Castrol Power 1 Racing 4T for R 70 a litre and want tu use it in your bike buy as much as you can afford to stockpile. The price is ridiculously cheap and I'm a bit worried it might be a limited time offer (?).
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 27, 2012, 11:29:43 am
Thanks Le Cap, that's what I needed, only 17k km engine was running well before she stood.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 27, 2012, 11:43:36 am
This dude hotted his 93  :o
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 27, 2012, 11:59:15 am
That is one killer amount of voomah for an oldtimer thumper .... that thing will wheelie like a MAD thing !!! :salut:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 27, 2012, 12:19:32 pm
Welcome back Veemax, where have you been DR'ing? Yeah that bike uses a XR650 aftermarket piston, TM 40, custom big valve head and custom zorst header with GSXR1000 can , 738cc
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 27, 2012, 03:34:35 pm
So simply you get two TDC's. If the first is right after the exhaust stroke the exhaust valves will be open. The following TDC - you'll have all the valves closed. Yes?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 27, 2012, 03:35:26 pm
Welcome back Veemax, where have you been DR'ing? Yeah that bike uses a XR650 aftermarket piston, TM 40, custom big valve head and custom zorst header with GSXR1000 can , 738cc

Let a TM40 slip through my hands today...will try to dyno, slightly mod carb and take out snorkel
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 27, 2012, 10:28:57 pm
Welcome back Veemax, where have you been DR'ing? Yeah that bike uses a XR650 aftermarket piston, TM 40, custom big valve head and custom zorst header with GSXR1000 can , 738cc

Planning similar rebuild in future for my 93.

Can hardly wait, It;s going to frighten a few of the newer bikes - twins included.

Can you post me a link to this guy?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 28, 2012, 09:49:23 am
I don't know how to post a link, but if you google "post your dyno sheets thumpertalk" it will take you to the page, also check out mxrob.com
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 28, 2012, 10:02:24 am
LeCap, Makro in JHB has got Castrol edge 10W60 fully synthetic API SL oil, 5L for R280. Is this good oil for an old DR?this oil at midas cost almost R500...

Can also get Motal 5100 10W40 4T, FL at starting line in Edenvale for R300. It says it's got some technology for wetclutches-smoother shifting

Any comment on where to get good mirrors for the DR? Mine is cheap aftermarket and the one especially vibrate too much, they aren't high enough as well
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 29, 2012, 02:35:55 pm
The Castrol Edge should not do any harm as long as it's API SL.
I'd still rather use the Motul 5100 which is JASO MA spec means specifically fornulated to work with wet clutch and look after your gears.
Non JASO MA oil might degrade rapidly in your bikes gearbox. Apparently some car oils don't like this and little might be left of your fancy 10W60 spec at the next oil change.

JASO MA takes the guesswork out of the equation.

If you use Castrol Edge check with every single batch that it was not "upgraded" to API SM. Most countries outside of SA sell Castrol Edge 10W60 with API service class SM. Castrol Edge 5W40 afaik is exclusively available as API SM

Good mirrors = OEM = pricey
Bad mirrors = aftermarket = cheap
Two separate equations. No part of one can be substituted into the other. Except "pricey" can be substituted for "cheap" at will ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 29, 2012, 04:35:05 pm
Just a quick one guys, does your headlight come on with the ignition or after you start the bike?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 29, 2012, 04:38:52 pm
With ignition.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 29, 2012, 04:48:56 pm
Seperate light switch for on and off.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 29, 2012, 07:25:38 pm
Wierd, no headlight and I changed no wires as yet!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 30, 2012, 08:44:08 am
The headlight does (should) come on when you switch on the ignition.

The bikes battery powered electrics do actually not "know" if the engine is running or not. The engine uses a magneto system (source coil & trigger) & some electronics to create and time the spark.

Both old DR650R / RE / RS / RSE (type SP41 - SP45) as well as DR650SE (type SP46) came with light switches or no light switches - depending on the country model.

If your bike does not have a light switch: Tap into the starter button circuit and use the tap to trigger a five point relais: Run the GROUND lead returning from the headlight over the "open when triggered" relais contact. Your light will now switch off automatically when and for as long as you hold the start button making some extra cranking power available to the starter and reducing stress on the battery.
Less than R 100 in bits and parts. Less than an hour to make.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 30, 2012, 09:00:10 am
I have a toggle switch to manually turn off the headlight , installed by the previous owner, and see no reason not to leave it there, a funny thing happens, when it's off, the blue highbeam indicator light burns, which is actually quite handy as a happy coincidence  :)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 30, 2012, 09:43:52 am
Set the valve clearances this weekend...without experience this can take a while... thing is that if you get them exactly right - the feel guage should it seems not come out between valve and rocker arm TOO EASILY. Someone told me the feeler guage should ALMOST be pinched but not so that you can't get it in again after it's been set.

The issue here for me was when I finally tighten the nut  - it goes tighter than what I had it. So...you have to set it too loose almost and then as you tighten it you hope that it is purrrfect. Took a while. There's no way you can hold the thing steady with a screw driver when you tighten the nut good, no ways.

My feeler gauges are car one's - the long thin ones, and make life difficult. Anyone know where I can get one's that look like those supplied by Suzuki for the DR's?

Well, I believe I got it in the end. I had a look at the exhaust flange as well when I took it off, that weld there DEFINITELY would restrict air flow, so I took a file and now it's nice. The plugs also, heard that getting the electrode to face the inlet ports can make engine more efficient. So, I hoped for the best and marked the plugs with a permanent marker - where the electrode is. Got it in, and it is almost pointed toward the inlet ports, so good...

Got the right plugs from Full throttle...man, I don't like shopping there.

I need an exhaust clamp. Got one but it was too big. Problem is that the can is too wide (where the it connect to the header). I took angle grinder and made slits so tightening it would taper can to fit header without leak. Anyone knows of a DIY solution of exhaust clamp?

Also took out the snorkel. I suspect the carb is running to rich. We'll see. Thx LeCap for advice. Would be good to get oil that helps shifting. It comes in 4L though, so with change of oil filter that does not give me two oil changes, just less than that. PAIN. Would have to buy another bottle for that 150ml the oil filter takes.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 30, 2012, 09:49:50 am
LeCap, do you know of other oil that is made to help shifting - wetclutches besides MOTUL?

Need to change sprockets. Used Gearing Commander to decide on 14 (front) and 40 (back). Will up the revs slightly in 2nd. I don't have a TM40 carb...(!) so I want to smooth out the jerkiness at low revs (below 3000rpm). Riding around town - you can always open up everywhere you know?

Any comments on my sprocket choices? also with regards to where to buy and expected prices? thx
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 31, 2012, 10:07:25 am
I use Castrol ActEvo 4T SAE10W40 JASO MA
Got stock again after some shortage in Jan.
You can get it in 1l containers for around R70 from bike shops. Sometimes considerably cheaper IF you can get it in places like Makro.
I sell it for R 68 / litre
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on January 31, 2012, 12:41:02 pm
I use Castrol ActEvo 4T SAE10W40 JASO MA
Got stock again after some shortage in Jan.
You can get it in 1l containers for around R70 from bike shops. Sometimes considerably cheaper IF you can get it in places like Makro.
I sell it for R 68 / litre

Will look into that oil, thx. Got a question there about sprocket size. This is the issue it seems: I got a DID 525 V8 chain with the bike when I bought it, separate in box, brand new. GREAT!

Now, I have to replace sprockets and tyres. I'm asking the guys at chaintech what sprockets I should buy. They say the 1993 DR650 should take a 520 chain. I need to do some kind of conversion for it to take a 525 chain and sprockets...Here's their reply:

"A 525 pitch conversion means, you get the part number of the sprocket your bike takes with its specific measurements and splines and bolt holes, then you take those specs and match it up according to a 525 pitch.  Standard, the bike comes out in a 520 pitch and I have just tried to find matching measurements in a 525 and there is no part numbers with the same measurements.  I can help you with 520 pitch sprockets and chain.  That means you HAVE to use a 520 pitch chain as well.!"

Does anyone know anything about pitch and what not above here? You telling me that my brand new DID chain does not fit my bike?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 31, 2012, 02:30:57 pm
Sorry Volroom, can't help with pitch story. I have, over the years, developed a strategy of ALWAYS shopping for parts with a sample in hand. I always get the right thing. I wouldn't change sprockets if you got given the wrong chain. You'll make a lifetime of fishing in the wrong river. I would urge you trade the chain.

Having just said that, I ordered a new front disk brake rotor from Suzuki , with no sample !

The model numbers and codes for this generation DR are all over the place, so I've just phoned in with my VIN # .

Yes it IS a 1994. The designation of mine is DR650RE , with year code "r" for 1994 , so it's a DR650RER supposedly.

The internet is a great place for total misinformation. FINALLY, I know what my bike is, from the official Suzuki Fiche.

My new disk is inbound from Japan. With my Frequent Flyer discount it's around R2800.

The confidence factor in the metallurgy of the clones is a ZERO. On brakes, I take no chances.

I'm in on this bike ... call it R40k.

No matter how you hack it, to get a mechanically new and completely reliable machine on the road, with a whole new life expectancy from a whole freshly rebooted platform , it is unlikely you will end up spending any less.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 31, 2012, 05:08:21 pm
Well, this is what she will look like when done......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 31, 2012, 09:26:06 pm
Read something rather interesting on throttle response. replace DR throttle tube with one from a Yamaha R-6 anyone heard of or care to comment on this?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on January 31, 2012, 11:44:49 pm
...Got a question there about sprocket size. This is the issue it seems: I got a DID 525 V8 chain with the bike when I bought it, separate in box, brand new. GREAT!

Now, I have to replace sprockets and tyres. I'm asking the guys at chaintech what sprockets I should buy. They say the 1993 DR650 should take a 520 chain. I need to do some kind of conversion for it to take a 525 chain and sprockets...Here's their reply:

"A 525 pitch conversion means, you get the part number of the sprocket your bike takes with its specific measurements and splines and bolt holes, then you take those specs and match it up according to a 525 pitch.  Standard, the bike comes out in a 520 pitch and I have just tried to find matching measurements in a 525 and there is no part numbers with the same measurements.  I can help you with 520 pitch sprockets and chain.  That means you HAVE to use a 520 pitch chain as well.!"

Does anyone know anything about pitch and what not above here? You telling me that my brand new DID chain does not fit my bike?

First: DID 525 V8 chain & GREAT! are two things rather far apart from each other: The reason why you got it with your bike was because some smartie knew it's a shite chain with a proven track record of snapping way before reaching its wear limit and without warning. The chain came new fitted to a DR650SE (probably the bike the previous owner of your bike replaced yours with).
He did the sensible thing (like me) and took the chain off the brand new bike and fitted something decent like a DID VX. Then he did the not so sensible and gave it to you making you believe you snapped up a bargain ::)

Now go and give it to someone you don't like :evil6:

520, 525, 530, 532 and 50 chains all share the same pitch (distance from pin centreline to pin centreline). It is 5/8" or 15.88mm.
The difference lies in the chains gauge (basically the thickness of the sprockets) which is:
520: 1/4" = 6.35mm
525: 5/16" = 7.94mm
530, 532 and 50: 3/8" = 9.5mm
532 being some "extra heavy duty" stuff uses proprietary sprockets due to its unique (larger than all other 5/8" pitch chains) roller diameter. It is externally almost identical to a 530 and 50

630 (3/4"x3/8") 19.05mm x 9.5mm was a chain used for some heavy late 70's two wheeled sows like Katanas and CB750KZ ::)

Long story short: Just get the 520 chain annd sprockets for your bike. The 525 gauge sprockets of the DR650SE 1996 and later might fit (it does work the other way around).
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 01, 2012, 08:04:41 am
Well, this is what she will look like when done......

Brilliant ! Wow ! And you'll keep all the brand-loyal Propeller / Orange fixated riders wondering What The Hell Is That ?

I think I'm going to epoxy-fill the "Suzuki" on the oil filter cap , it's about the only insignia left, and turn my desert rat into a mystery for all but the Informed : ) : )

I think maybe an Acerbis tank will be a nice present to myself , check the exchange rate .... now is the time. But the magnetic property I will miss...ho hum....

Oh yeah, and that fender is way cooler than the stock.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 01, 2012, 08:22:15 am
Thanks Veemax  :biggrin: Ja keep em guessing, I hope the SM mudguard keeps the mud splatter at bay, I will be fitting a shorty screen at a later date.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 01, 2012, 08:24:43 am
The bike looks awesome. The only thing I find a bit irksome to the eye is the yellow reflectors on the forks and swingarm?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 01, 2012, 08:32:22 am
Yeah they will be going, want to actually make up some white fork protectors to "fatten " up the front end a bit, still have to do the wheel areas, so will be re-coating spokes, spraying swing arm, checking bearings and bushes etc...... Not done yet.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 01, 2012, 08:36:32 am
Why not get the whole disc and fork protector like on my bike, it is available still from suppliers, and looks very cool, especially with the white theme on your bike...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 01, 2012, 08:38:36 am
I may just do that, any idea on the cost?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 01, 2012, 08:48:52 am
$70 + Shipping looks like : http://www.procycle.us/bikepages/dr650.html

Sorry to damage your credit card by sending you to THAT page, just too many farkles all in one place!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 01, 2012, 08:54:36 am
Did the post 96 ones fit? If so it will have to wait for phase 2 of my re-build, ie. when I sail and make some more bucks again

I damaged my card recently at pro-cycle with my tank, vapour etc  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 01, 2012, 08:57:49 am
My bike came with them, I'm not sure if they are original or the post '96s. They are just held on by cable ties so if the forks and discs are the same diameter I can't see why they wouldn't?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 01, 2012, 09:03:31 am
I've been to my workshop and measured both old/new DR's lower stanchions at 51-52 mm , but that's where the similarity ends.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 01, 2012, 09:05:54 am
I will pooratech PVC it for now, will prob use the same for a tool tube.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 01, 2012, 11:14:14 am
...Got a question there about sprocket size. This is the issue it seems: I got a DID 525 V8 chain with the bike when I bought it, separate in box, brand new. GREAT!

Now, I have to replace sprockets and tyres. I'm asking the guys at chaintech what sprockets I should buy. They say the 1993 DR650 should take a 520 chain. I need to do some kind of conversion for it to take a 525 chain and sprockets...Here's their reply:

"A 525 pitch conversion means, you get the part number of the sprocket your bike takes with its specific measurements and splines and bolt holes, then you take those specs and match it up according to a 525 pitch.  Standard, the bike comes out in a 520 pitch and I have just tried to find matching measurements in a 525 and there is no part numbers with the same measurements.  I can help you with 520 pitch sprockets and chain.  That means you HAVE to use a 520 pitch chain as well.!"

Does anyone know anything about pitch and what not above here? You telling me that my brand new DID chain does not fit my bike?

First: DID 525 V8 chain & GREAT! are two things rather far apart from each other: The reason why you got it with your bike was because some smartie knew it's a shite chain with a proven track record of snapping way before reaching its wear limit and without warning. The chain came new fitted to a DR650SE (probably the bike the previous owner of your bike replaced yours with).
He did the sensible thing (like me) and took the chain off the brand new bike and fitted something decent like a DID VX. Then he did the not so sensible and gave it to you making you believe you snapped up a bargain ::)

Now go and give it to someone you don't like :evil6:

520, 525, 530, 532 and 50 chains all share the same pitch (distance from pin centreline to pin centreline). It is 5/8" or 15.88mm.
The difference lies in the chains gauge (basically the thickness of the sprockets) which is:
520: 1/4" = 6.35mm
525: 5/16" = 7.94mm
530, 532 and 50: 3/8" = 9.5mm
532 being some "extra heavy duty" stuff uses proprietary sprockets due to its unique (larger than all other 5/8" pitch chains) roller diameter. It is externally almost identical to a 530 and 50

630 (3/4"x3/8") 19.05mm x 9.5mm was a chain used for some heavy late 70's two wheeled sows like Katanas and CB750KZ ::)

Long story short: Just get the 520 chain annd sprockets for your bike. The 525 gauge sprockets of the DR650SE 1996 and later might fit (it does work the other way around).


OK, so the pitch is not the problem. 525 chain would fit post 96 sprockets - thickness wise? So, if I would want to keep the chain, I'd have to get hold of post 96 sprockets - right?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 01, 2012, 05:53:51 pm
Oh, I nearly forgot to post my annoying pic taken by the missus yesterday , she on her Xlx350R and me on my "other" , much forgotten DR, at our favourite spot on the south peninsula. Note use of backlight to obscure my handsome features in an appropriate forum-paranoid way.

I'm heading off tomorrow down here in CT to help Wildcoast secure his exhaust , with my 94 DR as a mobile jig. Geoff is an amazing guy he remembered me from about 5 years ago , he must see many bikers every day.

I'll take my camera and by tomorrow afternoon should be able to post pics of WC's zorst on my bike , wish us luck.

 (http://i971.photobucket.com/albums/ae199/Veemax/31Jan2012.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 02, 2012, 07:13:14 am
aaaarrghhhh! another one... One day, I'll return.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 02, 2012, 07:27:07 am
...Got a question there about sprocket size. This is the issue it seems: I got a DID 525 V8 chain with the bike when I bought it, separate in box, brand new. GREAT!

Now, I have to replace sprockets and tyres. I'm asking the guys at chaintech what sprockets I should buy. They say the 1993 DR650 should take a 520 chain. I need to do some kind of conversion for it to take a 525 chain and sprockets...Here's their reply:

"A 525 pitch conversion means, you get the part number of the sprocket your bike takes with its specific measurements and splines and bolt holes, then you take those specs and match it up according to a 525 pitch.  Standard, the bike comes out in a 520 pitch and I have just tried to find matching measurements in a 525 and there is no part numbers with the same measurements.  I can help you with 520 pitch sprockets and chain.  That means you HAVE to use a 520 pitch chain as well.!"

Does anyone know anything about pitch and what not above here? You telling me that my brand new DID chain does not fit my bike?

First: DID 525 V8 chain & GREAT! are two things rather far apart from each other: The reason why you got it with your bike was because some smartie knew it's a shite chain with a proven track record of snapping way before reaching its wear limit and without warning. The chain came new fitted to a DR650SE (probably the bike the previous owner of your bike replaced yours with).
He did the sensible thing (like me) and took the chain off the brand new bike and fitted something decent like a DID VX. Then he did the not so sensible and gave it to you making you believe you snapped up a bargain ::)

Now go and give it to someone you don't like :evil6:

520, 525, 530, 532 and 50 chains all share the same pitch (distance from pin centreline to pin centreline). It is 5/8" or 15.88mm.
The difference lies in the chains gauge (basically the thickness of the sprockets) which is:
520: 1/4" = 6.35mm
525: 5/16" = 7.94mm
530, 532 and 50: 3/8" = 9.5mm
532 being some "extra heavy duty" stuff uses proprietary sprockets due to its unique (larger than all other 5/8" pitch chains) roller diameter. It is externally almost identical to a 530 and 50

630 (3/4"x3/8") 19.05mm x 9.5mm was a chain used for some heavy late 70's two wheeled sows like Katanas and CB750KZ ::)

Long story short: Just get the 520 chain annd sprockets for your bike. The 525 gauge sprockets of the DR650SE 1996 and later might fit (it does work the other way around).


At Suzuki they seem to think the 525 chain will work with 525 sprockets. If they say so, I'll order and if they don't fit it's their problem. I don't feel like forking out R900 for a chain right now. Have to get new tyres, and do a dyno. I understand the 525 V8 is not the best chain out there, but it is a DID. It is an O-ring chain. Maybe it'll last..fingers crossed. Seems Vstroms has this chain as OEM.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 02, 2012, 02:07:28 pm
Wildcoast , your exhaust is soon under construction. Geoff held up your old pipe, took one look at my DR mounts, and knew exactly what to do , didn't need my bike further.

He also had precisely the right hardware on hand for my (s50) problem , so I'm to go back for a 'fitting' on that bike when convenient.

The man sure has all the answers , it's called COMPETENCE, and it's getting rare these days.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 02, 2012, 04:11:23 pm
Is that your numberplate at the back of your topbox, Veemax?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 02, 2012, 05:04:00 pm
Ja, sadly so, here in the Cape the Metro Cops have gotten all childish about SABS plates. I have a smaller plate ( under the fender ) I often use when away from childish metro cops, in the sanctuary of the Karoo, or Namibia or whatever , where milking money from the already over-taxed, is not a problem.

This ugly plate from some angles is not so obvious hinged onto the top box , (which is a handy tool around town) , the plate forms a backup closing bungee with a rubber bonnet catch.

For very serious dirt I only use soft luggage and my elegant single camlock tie-down , and my , gasp, ILLEGAL plate.

Why can't we have small plates like the USA ? For fucks sake the SABS Aesthetic Eyesore is just one way to make your bike look KAK.

I once took on SABS about SANS 1116 spec, they were actually responsive, but I find it too exhausting to tackle officialdom who these days don't even speak the language of , how shall we put this, the modern, international world.....





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 02, 2012, 05:08:18 pm
And there is no way in hell I am putting an SABS Airbrake on this machine !!!!

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_2980.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 02, 2012, 05:25:07 pm
NICe... :drif:

SAZOOK foreva, eh?

That thing must go..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 02, 2012, 06:01:45 pm
Thank you very much indeed Veemax, just tried to give you a call to thank you personally for your effort, much appreciated  :thumleft:

Yeah, speaking to Geoff he certainly seems to know his business.

I actually am like a kid at Christmas time at the moment, just wanna fire the old lady up now  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 02, 2012, 06:09:04 pm
That bandit is the Bizznizz,  :drif:

Agreed Volroom , Suz box for ever  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 02, 2012, 08:23:29 pm
Wildcoast I got to my phone 0.00003 secs after it switched to voicemail , got yer message, you are most welcome buddy ! Really no biggie my side as I wanted to see the man anyway.

Ja that Bandit is a wolf in sheeps clothing , to give you a clue, the stock main jets are 100 and it runs 122 outer's/124's inner's .... motor never opened but it BREATHES , makes 'Busa torque at 110Nm and wheelies like a wild beast , it makes you a very, very bad man. There is a dark secret few know, advance the timing 3 deg, and it wakes up and GROWLS from it's cylinders. ( And violate the airbox, short pipe, etc etc !! ) Leaves my brother-in-law's GSXR1100L for dead all the way to 265kph, then the Gixxer, eventually, comes horsepowering through. By that time it's Game Over in the real world.

Yes I am , after 30 bikes + in my life , .........I iza Suzook man......... to the bone !

Now, just wish I could tweak the ignition timing on a DR, but that would be an engineering feat not worth the effort ... damn.

Hey I saw a dude on a ratty 92-94 DR in the traffic today , I was waiting at the lights on his left. The classic double-take from inside his helmet when he saw ole Velvaglo was, in fact, a kindred bike, was bloody hilarious. His bike, was , shame man, very tired and very smoky, but hanging in there .... if it was anything less than a DR it woulda been long dead. His plate was so black with soot I couldn't see where he came from. Dude, if you are out there .... respect mon ....but hey, rebore and rebirth it man !!! :3some:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 03, 2012, 12:12:52 am
...I understand the 525 V8 is not the best chain out there...

Do NOT use it. A cracked crankcase costs more than a decent chain.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 03, 2012, 07:32:02 am
Fantastic, now I just have to do valves etc, before my pipe arrives, good motivation.

Had someone keen to buy my DR , she is not for sale!
Keep a look out for one for the guy, he is on the forum as well.

Yeah having owned a gs650 shaftie and GS850g I basically decided there is no other bike but Suzuki, besides an old airhead BMW but thats another story, they just seem built better and have tougher engines than most other bikes.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 03, 2012, 09:23:42 am
Snap ! Had a GS1000S @ Stage 3 Yoshi big bore , and not so long ago a GS1000G , one of the most robust bikes ever made, those !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 03, 2012, 11:59:35 am
...I understand the 525 V8 is not the best chain out there...

Do NOT use it. A cracked crankcase costs more than a decent chain.

I'm trying to sell it. Theotherguy has had this chain on his bike for 24k km. He is meticulous about maintaining the chain. Just saying, it's not definite that it'll break
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 03, 2012, 03:25:26 pm
I did valve clearance and balancer chain adjustment today, noticed metal filings in magneto cover (sump) is this normal?
Nothing in main engine oil I drained and oil filter .
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 03, 2012, 03:29:28 pm
I did valve clearance and balancer chain adjustment today, noticed metal filings in magneto cover (sump) is this normal?
Nothing in main engine oil I drained and oil filter .

How do you adjust balancer? Do you have pics perhaps?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 03, 2012, 03:48:40 pm
I did valve clearance and balancer chain adjustment today, noticed metal filings in magneto cover (sump) is this normal?
Nothing in main engine oil I drained and oil filter .

Are they magnetic ? ie Ferrous or Ally Nyum Nyum ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 03, 2012, 09:00:51 pm
...I understand the 525 V8 is not the best chain out there...

Do NOT use it. A cracked crankcase costs more than a decent chain.

I'm trying to sell it. Theotherguy has had this chain on his bike for 24k km. He is meticulous about maintaining the chain. Just saying, it's not definite that it'll break

The new DR's that came with this chain wore it to the point where the chains were unevenly stretched within 12,000km or less.
I had one snapping without warning after doing only 11,000km. Threw another one away at the same time and rode the bikes home from Norhten KZN to CT with combined harvester type roller chains for less than R100 a tot (from Bearing Man, due to lack of new sprockets) . We had to tighten the roller chains every single day and throw them away after 3000km but at least they did not snap.

Might not be definitse that it will break but I would not take a chance and won't recommend it neither.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 03, 2012, 09:28:22 pm
Thumpers , compared to , say, Fours, require tougher drive components for the same horsepower, because of the pulsing peak surges of those mighty pistons. I would never risk a virtually irreplaceable engine casing, or cataclysmic demise of an entire motorcycle, on so worthy a steed as an early 90's DR , by clinging in denial to a cheap chain.

Rather ride with an old, but proper chain, until the next payday !

Again, Le Cap shares his huge database of experience, for the good of us all, for free. Danke freundlich, Herr Expert!

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 08:33:31 am
They looked like aluminum num , Volroom, I followed the manual for balance chain.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 04, 2012, 09:15:31 am
Maybe it was a thrashing chain then ? Cam or Balancer ... so maybe you've fixed it ! ?

There is a neat trick this engine does, the alternator magnets act as a centrifuge, because it's "inside out"  , and micro ferrous particles get trapped on the inner surfaces of the flywheel. Neat huh !

Probably another contributor to the legend of tenancity of this engine.

I don't suppose you thought to wipe down the magnets while you had the cover off ? The grey goo that comes off is the engine cleaning itself of all the nano/micro metal that whistles through the filter.

Suzuki....rocks man !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 11:54:23 am
Yes, wiped it off, those shavings were kinda a metalic sludge, opened clutch up this morning, no filings in there thankfully, my clutch is different to the diagram on the manual, the thick plate is under a perforated plate that is wired to the outer hub (not the basket), from there all the plates are as per the diagram?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 11:59:00 am
Like so.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 12:03:57 pm
that thick plate is supposed to be above parts 6 and 7? those washers that you warned me about Veemax?
So I have no wave washer or wave washer seat in my clutch????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 04, 2012, 12:15:38 pm
Oh sh^t ! WTF you got there bud ????  Now is the time for some careful research. I would suggest a trip to your locak Suzuki parts man, VIN and Engine number in hand, is the only way through to light and logic here !

Is that wire thing 'continuous' ? Does it rest in a slot or what ? Does it 'look' OEM ???

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 04, 2012, 12:33:53 pm
Has the "thick plate" got a larger ID than the other plates ? If it's the right plate and those parts 6&7 are missing, you have an abortion...shall we say, a classic abortion, you will not be the first to open an engine and be greeted with this, I've had it TWICE !

LS650P Savage and 94 DR appear to have the same clutch, with this same 'anti-rattle' or 'anti-shudder' odd configuration that okes who open engine loose the plot over !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 01:40:20 pm
Went to Suz, he has diagram for my bikes clutch, same as yours, so I ordered the parts I need, plus full set of new plates.
Does not really look OEM, No wonder it was slipping, plates in spec but glazed, prob from Kark set up to start with.  :dousing:

These bloody pre-96s DO HAVE SUBTLE DIFFERENCES IN THE CLUTCHES!!!!!
Check out www.cmsnl.com's microfisches for the clutches

Looks like I may have to order another washer, Oh well at least I have lotsa spares now , clutch, carb etc etc

I also need a ring wave washer it seems. it is  smaller than the parts mentioned above and fits between clutch plates

So 3 washer/washer seats missing in action.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 03:38:41 pm
The SAGA continues, this thing looks OEM, see pics, 1 where wire runs, 2 where it comes together on reverse side, 3 grooves to accept wire, 4 dissasembled with two missing washers and plate (plate Inside diameter smaller than other plates)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 03:57:13 pm
So waar, found it, part number 14.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 04, 2012, 04:16:52 pm
I cant for the life of me understand the Why and How behind that last oddball plate pair ... I guess some guy spent months if not years doing R&D around this thing. Meantime your rather offbeat model sure holds some surprises eh ?

Glad the Suz man cleared it up.  As my old colleague used to say Money Solves Most Problems !

Do not panic when you first ride off with your new clutch btw , expect it to be moerse eratic and behave horribly until it settles in.

Like you I renewed that whole stack. It's really, REALLY reassuring when you know you have the correct parts installed correctly, and a delight when the thing no longer slips ! YEAH. Back the way it was when it left the plant in Japan, before some confused guy with no manual porked it all up.

You know the RTFM rule huh ?

Read The Farken Manual !!!!  :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 04:19:06 pm
The Suzuki guy just ordered me the wrong parts  :deal:
I will call him monday, cancell the extra washers, order part 5, try find some similar wire, slap her back together and pray it bloody works  :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 04:22:15 pm
BTW the only manuals I have (I have two) both show the clutch as in Deepbase's download he put up.

I have no idea what rock my bike crawled out from under , but it's a mission to find diagrams for it, wiring , clutch etc.

Maybe it is the R&D model that escaped into the big wild world
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 04, 2012, 04:25:11 pm
I checked and rechecked with my Suz guy THREE times to make sure I was getting the right front disk, he was ALSO about to order the wrong part. It's tricky this model variant thing from this generation ...

And still , when the part lands I ain't paying until I slap my old disk on the counter for a dead match ....

We all know the automotive guys need , er, a little help sometimes .... ( we won't mention KTM )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 04, 2012, 04:26:27 pm
I'm taking your advise on Monday for sure VIN number for the dealer.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 06, 2012, 09:09:53 am
Veemax, I remember you saying that you've got a stage two conversion on your old DR, right? So, you cut the airbox? If so, can you gooi some pics - I'm doing it as well and need to know how to cut.

MxRob funny enough says that the bigger the whole the LESS dirty your airfilter becomes - would have thought the opposite to be true.

I've got the exhaust sorted, so dyno tuning and dynokit will be done soon. Will drill the slide of the carb and clip the spring - it the latter is a good idea? Seems controversial
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 06, 2012, 09:16:18 am
Slide drilled and spring cut are for throttle responce only, won't up the performance, have heard of weaker spring causing throttle to wind on a bit in rough conditions, dunno if you want that, accelerating by itself  when you hit a bump?

I have two springs, let me experiment first before you go and chop yours.

I am keeping my bike as stock as possible, not trying to turn it into a rocket ship , reliability more important than performance to me.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 06, 2012, 09:32:10 am
Ok, let me know what you think of cut spring. Reliability also key for me, doing stage two mod I think won't really make it less reliable. Only concern would be that you should clean your airfilter more frequently. MXrob by the way said that you have to cut proper hole - otherwise it makes a noise and somehow the airfilter becomes MORE dirty

Look at http://kientech.com/DJDR650AbMod.htm
To get idea of the hole.

I'll cut the hole soon. BTW - I marked my sparkplugs and tried to get the electrodes pointing toward the inlet ports - without using washers. Was lucky - pretty much. Also, I ground the exhaust flange weld - it was definitely restricting airflow.

Can't wait...

Heard guys talk about the front wheel lifting with the pumper carb - I mean, that is SERIOUS acceleration. I don't have the pumper carb, but getting anywhere close to that kind of acceleration...good stuff

Will try to adjust balancer and maybe also check compression (with gauge) before dyno tuning
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 06, 2012, 10:31:37 am
Remember my 94 DR is BONE STOCK but for a scorch pipe. But here are pics of my 08 DR ...airbox additional hole, 150 main, screen removal, header weld reduction ( note Superbike Solutions claim some degree of exhaust restriction at this point increases torque ! ) , and a Geoff Talbot pipe which is straight-through.

I ran a K&N for a while then went back to stock to not compromise my bikes longevity.

My DR against a bone stock DR of the same model belonging to my mate , leaves it for dead.

I would not drill the slide nor clip the spring , as the new DR slide has only one hole to save the needle .... as I've said before you don't want a twitchy throttle over rough stuff , I wanted more top end power and I got it, but I wanted the controlled power and economy of a stock 1/4 to 1/2 throttle.

I left the needle STOCK, it's lean yes but I tune for Hot and High and want range and economy when not racing at full throttle.

There is a flat spot during warm up to remind me I have mods , and also to ride like an intelligent person before optimum running temperature !

(http://i971.photobucket.com/albums/ae199/Veemax/DSCN3489.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/DSCN3497.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/DSCN3490.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 06, 2012, 10:41:34 am
Re the wire ring in the clutch: It's not continuous but rather some sort of a very flimsy circlip. Chances are good that it will give you hell when you try to fit it again (it gave me hell). Just throw it away as I did, no adverse effects noticable.
In theory I think it prevents the two washers from dislodging and causing some sorts of hassles which I don't think is really possible with the clutch & engine assembled & running. Might be a factory assembly line thing. (?)

Removing the mesh screen is not really advisable since it's the only thing that stops your engine from ingesting stuff (big stuff) if the air filter tears or is poorly fitted. Also prevents backfire from scorching the filter.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 06, 2012, 11:31:51 am
I am now aware of the screen as a backfire damper , and also read there is NO data suggesting screen removal adds any performance, if I did it all again the screen will stay.

I did a screen removal on my KLR back in 08 but that LOOKED restrictive ! ???

I am now of the school that a little top end breathing never hurt anyone , as we live in a country that tolerates aftermarket pipes , so why not ride a BIKE and not a goddamn sewing machine , but for the rest , ( oh my God am I getting old ??? ) ....stock works man ! If you wanna go faster get a faster bike !!!

 :laughing4:

I've been at track days where guys make poephols of themselves blaming their ZX10 for being slow because it's not the latest model ... and then you see an old guy blow them away on a ratty 5yr old CBR600.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 06, 2012, 12:04:50 pm
With regards to that wire in the clutch, see pic, part number 5 (ring wave washer) was missing, I have ordered it now, maybe the wire was put there as a bush mechanic fix to the missing part, the wire was damaged when I removed it , so if I need to I'll replace it with some "Mr Tooth" steel trace wire I use for gamefish  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 06, 2012, 12:17:44 pm
Thx for pics Veemax. AFAIK dynotune with dynojet kit, increasing airflow - would not necessarily increase fuel consumption. Will have to see I guess. I want extra oomph on my old thumper, as much as is possible without causing reliability issue and/or high fuel consumption.

What mods would affect reliability would you say?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 06, 2012, 12:28:55 pm
This is the advanced R&D WC airbox mod with Geoff Talbott intermediate pipe (arriving in about two days) 155 Dyno Jet main jet and needle
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 06, 2012, 12:30:40 pm
Will show pics of mine when it's done. WC, you gonna dyno tune as well? I just realised that trying to get that fuel/air mixture spot on without the necessary equipment is a guessing game. No thx
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 06, 2012, 12:36:43 pm
I recon I could guessing game it pretty close and spend money saved on juice and beer funds for a lekker ride.....

Just been RTFM'ing the 91 needs TDC on compression stroke for balance chain adjustment, does not mention this for other models is it safe to say you can set this with the piston anywhere?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 06, 2012, 02:42:00 pm
Guesstimating main jet for free flowing system over the years , sometimes supported by real Lambda data , I have arrived at a personal starting point of 1.07 x stock main ... but can be as high as 1. 22 on a Four ( extraction effect more pronounced ) , but more like an outside max 1.14 for a seriously gas flowed thumper.

I reckon with this cam I'd go 1.07 , maybe try 1.1 to find the upper end ? The old dead-kill highway trick is still a good tool for mainjet selection.

That means with Mikuni jets you'd be 147 to 151 on the main , with Dynojet sizes of course ....um..... you're lost !

On the reef of course, some Kentucky windage would be wise. Big thumpers breath crapply ANYWAY , so being on the reef is less of a disadvantage  to a thumper than to a screaming GSXR at 12000 rpm .... so maybe ponder this too ?

Can't see any benefit of TDC on the balancer chain, except maybe it eliminates any over-flick surprises while you have the doo-hickey loose !?? Maybe someone had a good reason to put that in the manual , so if you've gone to the trouble to RTFM , then may as well ATFM !!!! hahahahahhahaaaa.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 06, 2012, 02:46:56 pm
155 DJ is equal to just in between a 145 and 147.5 mikuni
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 06, 2012, 03:31:20 pm
Saved THAT in a flash ! Thanks. So I think your 155DJ is on the money for the reef then, beer and gas money ka-ching. One day when you get the chance you can validate everything on a proper calibrated dyno but that must be very close to optimum.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 07, 2012, 08:20:37 am
Fantastic, now I just have to do valves etc, before my pipe arrives, good motivation.

Had someone keen to buy my DR , she is not for sale!
Keep a look out for one for the guy, he is on the forum as well.

Yeah having owned a gs650 shaftie and GS850g I basically decided there is no other bike but Suzuki, besides an old airhead BMW but thats another story, they just seem built better and have tougher engines than most other bikes.

What kind of price was he wanting to pay for a DR, pre 1995?

I may be interested to let mine go as well as my XLV750R. Too many bikes My wife tells me.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 07, 2012, 08:53:20 am
SD thats what my wife said. Then after 25 years of marriage , I finally got her hooked. Now she has three.  S40 , S50, Xlx350R

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_0096.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 07, 2012, 10:01:51 am
Just got her Aprillia Pegaso 650
 And she wants me to get Blackbird up and gping then sell my OLD bikes for something new. I say if I spend a few rands my old DR will do more than these modern wonders will..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 07, 2012, 10:44:43 am
My Missus is too short for even a Pegasso ! I had to build her a very modified 350 to get her tootsies to terra firma ! Modern Wonders , been there, done that, only way I'd ride a Dual Purpose with more than one lung is if I was committed to lifting , even then I'd look for a Transalp / AT / old Super Ten / Cagiva with carbs and tappets preferably !

There is nothing better than a cheap and reliable old school bike that is already depreciated , when the going gets rough and dirty.

The KTM 640Adv was close to the ideal bike , but the DR is The One ... not even a waterpump to fail !

Hold onto that DR or you wail and gnash yer teeth in regret !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 07, 2012, 11:02:49 am
Just got her Aprillia Pegaso 650
 And she wants me to get Blackbird up and gping then sell my OLD bikes for something new. I say if I spend a few rands my old DR will do more than these modern wonders will..

Seems there's a lot you can do if your willing to spend the money on the Old DR. Procycles in the US
http://www.procycle.us/bikepages/dr650.html

Wildcoast posted that Dyno chart for modified DR. can't believe the diff! Just looking at the chart I'd think the 800GS would be left behind, the 990 and the modified DR would probably be head to head until 120-140km/h or something. Power to weight - the DR is much lighter than the 990

Yeah, the ideal DS bike - a modified DR - maybe..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 07, 2012, 12:11:46 pm
I had the first KTM Big Vee in Cape Town, and rode it 36 000km.  My personal fastest speed on dirt was 211kph.  My bike was very , very light and very, very powerful , I can bore you with 1000 mods and dozens of rides , how I nearly bought KTM as a business , how I fought with them, educated them, how I had to give them the freaking TSB's and the manual , how much better I was equipped than they were, to work on the bike, and long long boring stories regarding just how much work was required to make it go and keep it going, the price of parts, and what it was like to own a ferocious machine that was so much faster than everyone else's , how much of a twatwaffle I must have been , and how long I had to wait for my mates to catch up. All very purile and fundamentally annoying to everyone else.

Then one day I grew up and grew older and a whole lot wiser, and found pure joy in NOT being bloody Rambo , but having a bike that you could really, really trust, and by then everyone had a KTM, and strutted around in orange, about masses riding in groups, and GPS's and this forum and how too many people descend on small towns in huge hordes thinking how marvelous they are in their Dakar-Style gear and sip from their camel packs like they are Fabrizio Mioni himself , and piss off the locals with 70km dust trails and blocking petrol pumps and cafe's and terrorize animals and destroy environments, and act like inconsiderate City People with too much money.

heh heh heh

Then along comes modesty and respect and a nice sweet little bike that you can buy a clutch lever for that doesn't cost R850, that you can pimp and tweak and that goes surprisingly well for its age, and places you farrrrr outside the hordes and brand-conditioned marketing-swallowing Boorman wannabies , into the real world with valves you can set , carbs you can adjust, and no RoadSide Assistance because that is for Girls.

HAHAHAHAHAHA rant rant rant. When you've come full circle from XT500 to DR650 , had everything in between and outgrown it, and returned to the Truth and Essence of what is motorcycling, and prefer a small bike because it makes the world seem bigger , because big modern bikes make the world too small , then you get the right to hold an opinion, and also rant !

 :imaposer: :imaposer: :imaposer:



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on February 07, 2012, 12:18:51 pm
good quality rant.
i enjoyed it.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 07, 2012, 06:41:16 pm
good quality rant.
i enjoyed it.

+1
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 09, 2012, 09:24:23 am
This is the state of my gasket...it tore and at some places not looking good. I'm thinking I'll still try and reuse and add some silicon, not a lot. Comments?

Don't see any iron filings
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 09, 2012, 01:18:30 pm
Try to avoid the silicone.

Rather use the red hermatite gasket maker. A lot safer option.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 09, 2012, 01:28:53 pm
Try to avoid the silicone.

Rather use the red hermatite gasket maker. A lot safer option.

Thx, where can I get this?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 10, 2012, 09:15:52 am
...roadside assistance is for girls...
:laughing4:

I've currently got a HoesPoep2 to work on.
Doesn't even come with tools. ::)

"Hello this is BMW roadside assitance. How can we help you?"
"Oh hi, yah, I've just drowned my HoesPoop in the river crossing at Uitspankraal across the Doring River. Can you please send someone. And ask them to bring a spark plug socket wrench!"

Also very happy with riding DR's and KLR's after trying lots of different bikes over 28 years.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 10, 2012, 07:31:16 pm
An '85 DR600 for sale if anyone's interested. 

http://www.wilddog.za.net/forum/index.php?topic=90834.0
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 10, 2012, 09:54:14 pm
went to midas to go look for some proper gasket maker and they had gasket paper..great!
Cut out two. Will grease it bit when it goes back on. Got the motul 10W40 oil, castrol 4T 10W50 JASO MA is selling at Makro for R80 per litre for those interested
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 11, 2012, 12:38:10 pm
Did the same, cut gasket out of a sheet of gasket paper, used the black version of red devil with the gasket paper so I think its sealed.

Got my pipe and fitted it, will post pics later, thanks Veemax, excellent craftsmanship and fitted straight on.

Superdave, that guy bought a plastic 450, If you wanna sell the DR (Don't) just post it and it will go fast I think.

Volroom if you look at that site where the guy hotted his DR up, the power came at a cost, he cracked casings etc.
The DR you wanna hot up is the DR800, watch this space, always dreamed of my 100HP 170KG DR Big Dakar rep.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 11, 2012, 02:03:12 pm
Not keen to sell the DR.

Want to do some mods to move torque curve far more to the left.

A DR800 with 100hp and about 80nm to 100nm could be a serious OMB GSA contender acceleration wise and KTM eater. I dunno? But we can dream.

Would be a great machine especially if suspension was tweaked.

Yes what a machine that would be.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 11, 2012, 02:20:14 pm
Check out Stefan Hessler racing, his Big cleaned up the big twins in the Rallye Dalmatia in 2006 , they race any DS bike classes based on weight of bike
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 12, 2012, 06:54:18 am
changing fork oil - good idea, bad idea?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 12, 2012, 07:01:51 am
want to look into getting a night breaker light bulb for head light. Manual does not specify what kind it takes. Any ideas?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 12, 2012, 07:42:18 am
fork oil good idea
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 12, 2012, 07:44:48 am
I think it is an H4 globe.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 12, 2012, 09:04:02 am
New pipe fitted...I estimate about a 7kg weight saving by losing the twin pipe set up....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 12, 2012, 11:54:01 am
Nice pipe...remember the days when we had leaded petrol and a proper running engine was indicated by the white residue on the exhaust pipe
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 13, 2012, 09:18:52 pm
Soon I'll have the DR dynotuned. The guy said something interesting: that there shouldn't be any exhaust leaks and that the packing in the exhaust canister should be tightly packed. I guess if that wasn't the case ( the packing) that air could get into the baffle and mess with airflow or something. SO, about to drill out the rivits to check the state of the packing-add some of needs be. Does anyone have any relevant experience?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 14, 2012, 07:45:10 am
Who is doing the dyno?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 14, 2012, 08:25:23 am
freeze
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 14, 2012, 12:38:50 pm
freeze

Okay - I am frozen. Now should iput my hands up? :imaposer: :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 14, 2012, 02:07:19 pm
freeze

Okay - I am frozen. Now should iput my hands up? :imaposer: :imaposer:

No comment on his nickname..haha.
Charlie in Centurion - got his nr from theotherguy
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 17, 2012, 03:34:06 pm
Here is a picture of my DR650R before I lost the pipe on Himeville Road.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 18, 2012, 08:21:25 am
Finally got all my clutch parts from Suzuki, my clutch set up was all OEM, the wire is standard and is an OEM part, will be installing it today  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 18, 2012, 12:48:34 pm
Just back from 9 days in the bush building a 15 sqm roof structure under a tree destined to one day fall down and smash it .... hahahahaha.....goodie I see some progress while I've been gone !

NICE PIPE WC !

Just collected my new front disk rotor from Suzuki and again was pleasantly surprised they could dig out ... from stock ... a new O-ring for the oil return pipe ( on the left of the engine ).  Must be a special compound the old one is blue-ish the new one is black , maybe EPDM ?

With these installed the only last issue I have is the spring free length of the forks is 28mm under spec with sag , so I will conjure up some spacers to correct that on the cheapskate , and the last mechanical issues of my ole DR will be put to bed.

My Velvaglo Khaki DR parked outside Suzuki South this morning caused a bit of a stir , it was a busy morning with lots of guys testing the ZX1000 , but there was a gathering and commentary of note , one hardcore Austrian adventurer who crossed Africa a few times in a Jeep was particularly approving of this bike, and model in particular.

Always the first big comment from anyone who has done any real Africa time is " NO ELECTRONICS !!! "

Ja le Cap had a really good laugh at your HP2 chirp !!! I wonder how many bikes Uitspankraal has drowned ? : )

I got to know the owner of the farm Uitspankraal but for different reasons , pop rivet through my buddies KLR rear tyre. The shit that falls off bakkies is more of a threat to your days riding than most rocks and thorns.

The worst GS story I heard was poor ole Wayne F from Auto Atlantic drove a bakkie to deliver Roadside Assitance to a tourist on one of his MotoBerlin GS12's ....in Calvinia.

When he got there, he switched the kill switch to 'Run' , and hey presto , the fat flabby pig bike started. *sigh*









Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on February 19, 2012, 12:19:02 am
Ha Ha Ha that is a funny story happened to me aswell but no beemtroubleuuu call assistence i had to figure it all out by my self took me a while ha ha ha
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 19, 2012, 06:52:12 am
Lekka ride SuperDave! I'm thinking of planning a ride. The DR will be done in about 2-3 weeks time. I'm open in April. Maybe Namibie even Botswana. But if possible want to keep it to not more than 5 days...

Even if your not interested in a trip like this, what about a weekend trip? Some ideas, some suggestions, some comments? Sorry Veemax...this one is for the boys up in the vaal, but you can always come and visit your cousin..?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 19, 2012, 08:13:25 am
My wife and I are riding Apr 11-25 for 14 days straight , right smack Oh So Not In Easter or School Holidays etc , when we can OWN South Africa , and the weather is generally brilliant , and all the police are resting after pulling heavy shifts over Easter Madness.

I used this sweet spot before to ride the 29th Parallel , CT to Richards Bay across the country to Port Nolloth , and home , 4774 km in 6 days / 5 nights , the only place we needed rain gear was the on the N1 out of Cape Town to the top of Du Toits. But this ride was brain-out bad-ass 1200cc Suzook Oilheads ( spot the trend ? ) running BT54's , with average speeds that would have a Magistrate give you a snot klap.

Ja you Vaalies must enjoy yourselves when you can , shame man.  :pot: , but I still reckon when your bikes are at 100% we should convene someplace ( like my 'farm' would do ! ) , or someplace midway , and celebrate this ole DR good and proper huh !

I fitted the new O-ring yesterday oh so carefully and hey presto looks like my engine has gone all oil-tight , so now not only is it NEW but it doesn't emit hot-oil-smell that one tiny drop of oil can produce. That smell I guess old Brit bike followers consider normal !

I'm off to test an F650Se Husaberg this morning , 60 bhp on 112 kg , I'd better not ride a DR after that ...

It's not for me , been there done that with an SM610 ( kinda ) , but for a mate. What I like about our old DR's is they don't measure service intervals with an Hours Operation meter.

And servicing doesn't mean inspection of main crank bearings and rocker shafts .....

Ja the step from 45 to 60 bhp is not worth the spanner time to this ole toppie any longer !  :D

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 19, 2012, 03:09:40 pm
Veemax throw your fork springs into the bin.

For illustration have a look at the spring equation for coil springs and check what happens if a spring gets shorter with all other parameters remaining the same. Puting preload on will not help but rather collapse the springs further and possibly within hours or days. Also keep an eye on block length of the spring / spacer combo which must be less than what you've got between damper piston and cap when bottomed out else you will produce expensive scrap when hitting the first pothole.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 19, 2012, 08:42:33 pm
Thanks Le Cap , Progressive here we come. This ole DR is gonna WORK so I'm gonna take your advice ... and I hate a mushy front end even more than a mushy rear ( on , well , most things )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 20, 2012, 08:57:48 am
Progressive Springs Kit $ 103 ordered. Shipping $ 25 , not bad , eta < 7 days ??? Lands/clears at R1200.

Come this far , might as well go the whole way to a decent ride huh !

Must be a total of R42-R45k all in by now , but hey , sold my KTM for I think R61 000 , am happy, and the wear parts are NEW.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 20, 2012, 09:58:03 am
Mushy front end..besides taking out springs and checking length, what would be warning signs? Also-the danger of bottoming out on the front at speed? What might cause this? I'm no expert
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 20, 2012, 10:15:03 am
Since the Sani ride-I been so busy that I haven't had time to ride my DR. Also had top give some attention to my XLV 750 R failed fuel pump but that is another story.

So about aweek ago I climb onto bike - pull de compression lever and start process of kick starting my DR.

No life because when I release the decompression lever and kick it feels like it it still slightly open. IOW little to no compression.

Now I ask myself how can this beas the bike was running 100% until Igot home and switched the bike off.

So I thought - (but wasn't convinced) - maybe the valves clearances had loosened to such an extent to keep the valves open all the time.

Stripped off all the plastics -  and tank as well and have removed the inspection covers for inlet and exhaust valves.

Need to still drain oil and remove magneto cover - but somehow I think I am wasting my time. Is it possible that the compression ring could have broken if bike was running too hot and now that it has cooled down - broken?

I will check the valve clearance but suspectthey have tightened up and not loosened based on my preliminary inspection.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 20, 2012, 10:25:01 am
That happened to my bike, as well. After a 900km day pushing the bike hard, I got home, parked the bike and it never started again, no compression. The oil level was too low and the rings were chowed. Took a top end rebuild to fix. I am now very careful with checking the oil..!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 20, 2012, 11:06:44 am
Mushy front end..besides taking out springs and checking length, what would be warning signs? Also-the danger of bottoming out on the front at speed? What might cause this? I'm no expert

Sttering gets nervous especially on the brakes as the soft front changes & upsets the bikes steering geometry.

If the springs are really bad they will not fully extend the forks any more. Loosen upper triple clamp clamping bolt(s) & remove fork tube plug (front wheel in the air). If the spring does not push against the plug = if the spring is not preloaded the springs are scrap. This typically happens if the spring has sagged more than 20 - 40mm. You obviously have to remove any non oem preload spacers for this test.

I can get Wilbers springs for the old DR just as well as for almost each and every other bike build over the last 35 years or so with my next shipment.

Re the bike was fine, got home & parked now no compression: Normal scenario. The bike will run fine on very little compression. Once you switch it off it's finito and won't start again. Low compression will always cause starting problems first regardless if the compression is low because of worn rings & cylinder or leaking valves.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 20, 2012, 11:23:30 am
The Wilbers springs made a huge difference to my bike (and also replacing the fork oil at the same time). Much better handling on the dirt, and no more sag and dive on braking.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 20, 2012, 02:27:27 pm
I can confirm that my bike ran fine with buggerall compression , also used 145ml oil / 1000km ....then it SUDDENLY went into a massive decline.

Once open the full horror of wear and scoring presented itself. Quite amazing how well it behaved up until the point of caving in !

It was all traceable to a farked air filter of course , some homemade piece of crap ( one of the ) previous owner thought was a fitting filter !

But before a full rebore ... not a sticky valve maybe ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 20, 2012, 06:24:44 pm
@DeepBass- thanks for info.

@LeCap thanks for info - I am thinking of re doing whole motor top and bottom end. would it be possible to re-sleeve head and fit post 1996 DR piston? i.e increase the bore to 100mm?

With the stroke of pre 1996 DR - this should give me a capacity boost to about 710cc.

Is this do-able do you think?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 20, 2012, 07:44:28 pm


"If the springs are really bad they will not fully extend the forks any more. Loosen upper triple clamp clamping bolt(s) & remove fork tube plug (front wheel in the air). If the spring does not push against the plug = if the spring is not preloaded the springs are scrap"

So - just making sure, the fork tube plug - what's that exactly?Is it the top part of the fork legs that you can remove with ratchet and socket to get hold of the springs?

If that's the case, I loosen the triple clamp bolts - why?

Is this test as simple as removing fork plugs and seeing whether  the fork springs still push back when you fasten them again?
Sorry, just want to make sure. Was thinking of replacing the fork oil anyways

What does the wilber springs go for BTW?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on February 21, 2012, 10:37:26 am
@DeepBass- thanks for info.

@LeCap thanks for info - I am thinking of re doing whole motor top and bottom end. would it be possible to re-sleeve head and fit post 1996 DR piston? i.e increase the bore to 100mm?

With the stroke of pre 1996 DR - this should give me a capacity boost to about 710cc.

Is this do-able do you think?



Don't think this is doable since the DR650SE uses a sleeveless plated aluminium cylinder. The old DR650 has a cast iron cylinder liner.

Better to check if you can get some serious big bore stuff from Wössner or Wiseco. The DR750 piston and rings would be suitable to run in a sleeved cylinder too but I doubt you can make the 650's cylinder and crankcase cutout big enough to make space for the DRBig piston.
Gudgeon pin diameter is another consideration.

So - just making sure, the fork tube plug - what's that exactly?Is it the top part of the fork legs that you can remove with ratchet and socket to get hold of the springs?

If that's the case, I loosen the triple clamp bolts - why?
...
What does the wilber springs go for BTW?

Yes. You have to loosen the upper triple clamp because the clamp deforms the tube enough to pinch the plugs.

The springs are R1500 at the moment. I am waiting to see what the ZAR / € exchange rate does. Price might come down a bit in the second half of the year.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 21, 2012, 10:40:35 am
Thx LeCap, will check it out. Manual says 566ml front fork oil - that for both fork legs, or only one?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 21, 2012, 11:30:25 am
That's about right fork oil capacity but it's much better to use the airspace measurement  with the spring out.  I just did mine the other day the oil qty in the manual was about 20ml too much.

The head space is an important factor in the fork action due to it's compression
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 21, 2012, 04:58:13 pm
That's about right fork oil capacity but it's much better to use the airspace measurement  with the spring out.  I just did mine the other day the oil qty in the manual was about 20ml too much.

The head space is an important factor in the fork action due to it's compression

thx Veemax, don't see procedure to follow in manual. do you know if it's there?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 21, 2012, 05:11:58 pm
Don't think this is doable since the DR650SE uses a sleeveless plated aluminium cylinder. The old DR650 has a cast iron cylinder liner.

Better to check if you can get some serious big bore stuff from Wössner or Wiseco. The DR750 piston and rings would be suitable to run in a sleeved cylinder too but I doubt you can make the 650's cylinder and crankcase cutout big enough to make space for the DRBig piston.
Gudgeon pin diameter is another consideration.


@Le Cap- If I understand you correctly it may not be possible to machine the cast iron head to accept a 100mm sleeve?

I did have a look at the supplier of sleeves to Pro - cycles and they seem to have a thin walled very rigid cast iron liner range that might do the job.

I know they do a 97mm Wiseco Piston mod on the old DR 650. Do you think it would seriously weaken head to take another 3mm out the diameter?

It seems the DR650SE piston and old DR have same gudgeon pin diameter, waist height, etc and looks possible to fit on the 92 DR conrod.

Checking with Pro Cycle- but they can"t answer accurately as they have never done a 100mm bore mod.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 21, 2012, 05:12:09 pm
Yup !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 21, 2012, 05:16:42 pm
"@Le Cap- If I understand you correctly it may not be possible to machine the cast iron head to accept a 100mm sleeve?"

HEAD ? No , dude , NOW you're confusing me ! You mean CYLINDER surely ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 21, 2012, 05:18:49 pm
Yup !

 :( :( :( :(



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 21, 2012, 05:21:54 pm
"@Le Cap- If I understand you correctly it may not be possible to machine the cast iron head to accept a 100mm sleeve?"

HEAD ? No , dude , NOW you're confusing me ! You mean CYLINDER surely ?



You must check how confused I am?

Been a long day and at this point a head is a barrell is a cylinder is a block is whatever. :thumleft: :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 21, 2012, 05:23:03 pm
I should clean up my act, the YUP is to Volroom on the manual includes the headspace measurement ....

But interested in the BIG BIG bore idea of yours , however , without the casings and stuff on the bench, we're all gonna be speculating...

But hey, cat iron liners rock , nicasil sucks .... it would be fun to push the limits eh ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 21, 2012, 11:08:39 pm
I should clean up my act, the YUP is to Volroom on the manual includes the headspace measurement ....

But interested in the BIG BIG bore idea of yours , however , without the casings and stuff on the bench, we're all gonna be speculating...

But hey, cat iron liners rock , nicasil sucks .... it would be fun to push the limits eh ?

When cylinder is off- i am going to seriously check out possibilities of 100mm bore.am sure pistonwillfirif head can besafely re machined.

And then some other tricks to improve cooling and reliability and make some power... :peepwall:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 22, 2012, 08:32:20 am
to quote someone with a good turn of phrase , " The DR bottom end is as reliable as an ANVIL "

I reckon with a larger oil cooler ( like the newer DR ) , high compression ( 10.2 - 10.5 : 1 ) , a big bore , expanding link pipe exhaust , open airbox , pumper , and a bit of head flowing and exhaust header cleverness , you could wake that beast within BIG time.

The great thing about these oldtimers is if yer gonna look for a sacrificial Lamb , you are working off a budget platform , but a model with plentiful spares and spares bikes with which to stock your garage ...

My DR with 30 000 miles on the crank , abuse and neglect , had ZERO and I mean ZERO big-end play when the top end was off.

When you look at the strength of those components you wonder how far you could push it !

I recall the old misty days of the GS750 , you could put a blower on that bottom end and go to 150 bhp with a bone stock mill , if you did that to a Kawa it would fold like tin foil.

Old Suzooks are TOUGH.  100mm bore ... YEAH !!!  >:D >:D >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 22, 2012, 11:57:22 am
to quote someone with a good turn of phrase , " The DR bottom end is as reliable as an ANVIL "

I reckon with a larger oil cooler ( like the newer DR ) , high compression ( 10.2 - 10.5 : 1 ) , a big bore , expanding link pipe exhaust , open airbox , pumper , and a bit of head flowing and exhaust header cleverness , you could wake that beast within BIG time.

The great thing about these oldtimers is if yer gonna look for a sacrificial Lamb , you are working off a budget platform , but a model with plentiful spares and spares bikes with which to stock your garage ...

My DR with 30 000 miles on the crank , abuse and neglect , had ZERO and I mean ZERO big-end play when the top end was off.

When you look at the strength of those components you wonder how far you could push it !

Oh yes baby!

Some thermal coatings too and guess what...

Robust, reliable and a schocker for the newer bikes.

I recall the old misty days of the GS750 , you could put a blower on that bottom end and go to 150 bhp with a bone stock mill , if you did that to a Kawa it would fold like tin foil.

Old Suzooks are TOUGH.  100mm bore ... YEAH !!!  >:D >:D >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 22, 2012, 03:48:08 pm
hmmm. Manual does show what to do with the forks. I take it it's 566ml PER FORK leg. Usually sold in 1L bottles...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 22, 2012, 05:19:07 pm
This small hole in the airfilter spotted...looks almost as if it's supposed to be there...against my common sense. Can't remember if it was there when I bought new. Does it look familiar? If not, how can I close up that little hole - tell you what, I'm not going to fork out another R250 for stock airfilter anytime soon, bought that a couple of weeks ago!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 22, 2012, 05:57:12 pm
This small hole in the airfilter spotted...looks almost as if it's supposed to be there...against my common sense. Can't remember if it was there when I bought new. Does it look familiar? If not, how can I close up that little hole - tell you what, I'm not going to fork out another R250 for stock airfilter anytime soon, bought that a couple of weeks ago!

That must be the improved multi air and dirt ingress filter. :imaposer:

Very disappointing - dont look like it should be there at all.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 22, 2012, 09:31:17 pm
The question is , is that hole apparent on the inside too ? I'd plug it. But that's a bad show to release it from production like that.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on February 23, 2012, 06:19:46 am
Go to thumper talk ,a guy went big bore high comp on an older DR and picked up alot of cracks on casings etc, I think Procycle stocks a 670cc piston for older Dr's.

My bike has been started and runs, I seem to have "injured" my new tank , sending it off to plastic re-builders.
Headlight not working.
Very very frustrating times......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 23, 2012, 08:35:52 am
WC I made a split in my IMS tank mount way way wayyyy out in the bush completely alone ( new DR ) , I managed to make it to my farm and save the petrol by siphoning into a milk can ( very Voortrekker ! )

I had the whole night to contemplate a fix,  or the 47km walk to town !

By morning I was ready to execute a fix , using the polyethylene from a peanut jar lid , a fire poker, a small tin , and a gas stove.

I melted the PE in the tin , heated the fire poker , then melted the tank with the poker while pouring on the molten PE , it sealed up the tank and it's still like that today !

The real point of my story was I was a moron. I had tightened the rear mounts too tight and stressed the plastic. Today I use nice fat cable ties to anchor the rear with vectors that don't load the plastic. You've gotta watch those tanks , very reliable but don't think they are indestructable like I did !!

It's amazing how resourceful a lazy biker stuck in the bush can be , when it's either a two day walk,  or get clever .... ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on February 23, 2012, 09:04:29 am
as i recall (must be time to clean the airfilter again) the stock one also has that hole.
on the internal fitting there is a nipple which goes into it.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 23, 2012, 11:03:33 am
Aha ! ( who said NIPPLE ??? )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 23, 2012, 01:24:22 pm
as i recall (must be time to clean the airfilter again) the stock one also has that hole.
on the internal fitting there is a nipple which goes into it.

Thx.. AFAIK this might not be the stock filter for the DR. Got it from Suzuki, they looked at it, said it would fit and it does. If I don't see need for hole might use big washer that would cover or conjure up some other plan. thx. Hold in there WC...she'll be done soon. I know I can't wait - learning to be patient here
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 23, 2012, 05:48:32 pm
Go to thumper talk ,a guy went big bore high comp on an older DR and picked up alot of cracks on casings etc, I think Procycle stocks a 670cc piston for older Dr's.

My bike has been started and runs, I seem to have "injured" my new tank , sending it off to plastic re-builders.
Headlight not working.
Very very frustrating times......

Saw that casing story. Appears it turned out to be casting marks?

Don't know - but it also doesn't really make sense that the compression would cause this.If the cracks were cracks( pardon the crack) it may have been caused more likely due to heat I think.

Possibly what I should do is go up to next size piston  - Wossner make 10:1 pistons in increments of 0,5mm,that way if in years to come I suffer a failure then there is still meat left to go up another size.

I think do the cam profile they propose or as similar as possible, PowerKote everything that needs coating thereby improving heat transfer and longevity due to certain properties of the thermal coatings. Go with Wossner with slightly higher compression. Balance crank and if there is still some money left over look at TDM40 pumper carb. I do have exhaust can and probablywould have a new header pipe with 3mm increase in diameter made up. Fit bigger valves in head 32mm and 36mm. If necessary do some flowing of the head as well.

I reckon I should make between 15% and 20% more power and torque, than currently making and have a robust kannie dood responsive motor that will cruise cooler and be more economical as well.

So about 42rwbhp - 44rwbhp and between 62nm- 65nm. could be marginally more based on my calculations.

So what do you think?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on February 23, 2012, 06:38:20 pm
I'd think if veemax is getting 42rwbhp having done what he has done, you'd get a bit more! like maybe...50rwbhp! I would love to do mod like this, but money in the end decides. You have to think like Veemax, you might not get the money back but..your worth it!

If you do the rebuild, pls make new thread to keep us updated! My guess would be around 50rwbhp on the dyno
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on February 23, 2012, 10:04:06 pm
I'd think if veemax is getting 42rwbhp having done what he has done, you'd get a bit more! like maybe...50rwbhp! I would love to do mod like this, but money in the end decides. You have to think like Veemax, you might not get the money back but..your worth it!

If you do the rebuild, pls make new thread to keep us updated! My guess would be around 50rwbhp on the dyno

This is my thinking.Spend upto R20k on bike and motor and Iwill have a lovely machine without electronics that could possibly embarrass some newer and bigger bikes on and off road.

the grin factor is worth it.

Or I could sell DR and XLV and then still not have enough money to buy a bike that can do what my DR would be able to do when modded..

Such a motor will last a long long time and give much satisfaction too.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 24, 2012, 07:55:29 am
My hot KLR, to repeat the saga ... was measured at 45 rwBHP. I then had to rebore,  as the air filter literally fell off and the bore got scored ...so I went Schnitz big bore kit , settling on the 9.85: 1 choice for compression ... the bore was 102.5 for 685cc , ( which left me the option of going 701 kit at a later date ) . Then I radically altered the gearing with a much smaller rear sprocket. One could guess the power might have been at 48 bhp by then ?

Anyway, long story short, I sold the KLR to a mate , Simon

In a flat out burn on a deserted road in the Kouebokkeveld , my old DR, still with tired bore at that stage , with my wife on the back ... stayed with this KLR , he could simply not get away , the bikes were a dead match !

Which tells me Suzuki's claim for 46 beeaitchpee for this mill is no lie. The interesting thing about the old DR is it's stock gearing is very tall, and seems a dead match for my radically regeared KLR.

Now if you modify this DR for more power , you are going to struggle to gear it up for more speed, the laauuuuunch in first is already quite tall as you will have noticed. Hmmm. So, faster it might not be , but quicker through the gears for sure.

Certainly you have a KTM killer in the making , and I reckon as it looks like it already makes a genuine mid-40's bhp , you are looking at getting into the mid 50's with the mods on the table here !

As an aside , woo weeee, I see the tracking page for my Progressive Springs shows arrival half an hour ago at my local post office . yesssss.





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 24, 2012, 04:09:15 pm
Progressive Springs arrived and are IN.

Here how they look vs Stock ones ( which are 28mm under minimum free length spec )

(http://i971.photobucket.com/albums/ae199/Veemax/ProgressiveSprings.jpg)

I used the recommended spacer length of 3.75" , and went for a ride .... mmmm ..... bit too firm , the front is topping ... not everyone is a grossly fat American , clearly this starting point is for a monster dude.

I'll wittle away until it feels right

Good to be on the side of too stiff , at least now I can operate !

Landed cost R1203. Solves the problem of ancient squishy front end ...

Certainly the whole bike feels better , I just need to reduce the preload a tad and I'm on the money. More later.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 01, 2012, 07:30:38 pm
Need some advice...geese, doing things yourself can take frieken long! Anyways, at last got the sprocket and chain. Chain too long, it's a DID. VX2, LeCap..need to remove two links, normally I just moer the links out with a punch..not these. How do I get it out?

And, I'm having the bike dynoed nxt week. Would have bee last week already..but delays, delays. Question is: should I put on the dirt tyres on (mitas E09 rear) and have it dynoed with knobblie? I hear that dyno shows less horsepower and the knobbly gets chowed a bit. Currently I've got siracs on. Should I have it dynoed with the syracs, then the wheels have to come of again and chain..ok, I'm frieken LAZY!

Just getting the old sprocket off today drove me to my limits...nuts stripping and all
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 01, 2012, 08:36:50 pm
Angle grind the pins on the links you want out till they flush with the links, then wedge in a screw driver and moer it!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 01, 2012, 08:38:43 pm
Volroom - I fully understand your frustrations.

So I will be tackling the removal of motor and stripping to start my upgrade.

Waiting to hear about local availability of Wossner Piston- or I will import.

Ordered my gasket set yesterday - R900 complete OEM.

Spoke to motor engineers and a fellow biker who rides a Kawa 650 KLR, fitted with a Triumph piston nogal, that is now 702cc and makes 50rwbhp and about 60ft lb. Sounds high but I can't argue as he has his own dyno and a workshop at home that skriks vir niks,Says his bike is so lekker to ride now.

He is prepared to help me with my rebuild on the motor.

Yes Please! Let it be...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 01, 2012, 10:06:07 pm
Angle grind the pins on the links you want out till they flush with the links, then wedge in a screw driver and moer it!


That's the answer! thx!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on March 02, 2012, 08:39:29 am
Progressive Springs arrived and are IN.

Here how they look vs Stock ones ( which are 28mm under minimum free length spec )

(http://i971.photobucket.com/albums/ae199/Veemax/ProgressiveSprings.jpg)

I used the recommended spacer length of 3.75" , and went for a ride .... mmmm ..... bit too firm , the front is topping ... not everyone is a grossly fat American , clearly this starting point is for a monster dude.

I'll wittle away until it feels right

Good to be on the side of too stiff , at least now I can operate !

Landed cost R1203. Solves the problem of ancient squishy front end ...

Certainly the whole bike feels better , I just need to reduce the preload a tad and I'm on the money. More later.

Which springs did you buy? Why do they come without preload spacers ??? If the springs are too hard reducing the preload will not help much (same as the other way around).
Might be more promising to replace the preload spacer with a correctly sized additional spring.

Angle grind the pins on the links you want out till they flush with the links, then wedge in a screw driver and moer it!


Uh oh. Maybe time to invest in a chain tool? ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 02, 2012, 08:55:49 am
Hi Le Cap. Clearly this spring kit is multi-function/multi-model , it comes with a polymer spacer ( to cut ) and a fat table to select starting point preload, and some instructions and guidelines.

It is indicated for the 90-95 DR650S.

It took me three steps to achieve the sag I wanted ( full tank of gas ) , but with each cut it gets easier and the long Afrikaans words required trying to start the FINE thread via a 22mm socket + T-bar get shorter, as the spacer gets shorter hahahahah. It helps when you get smart and mark the starting point of the thread : )

Having the front end restored, if not enhanced, by these springs, has balanced the bike out nicely , less braking dive and more stable over rough terrain and at speed , due to... I assume.... what is now corrected geometry.

My bike is going so LEKKER now , while you guys work on yours mine is pointed towards the Karoo for a 700km ride.

Oh, one last niggle...maybe its fixed maybe it isn't : That Oil Return pipe from the head , the join at the head is a BITCH. I got a brand new OEM O-ring from Suzuki , and refitted the thing very very VERY carefully , with GREASE , as per the manual.

It seems to still weep.

Should I try with a sealer instead of grease ? What would be the best sealer ( hate silicone ) ....

Dammit I paid microscopic attention to the tube and the head surfaces , could find no fault , dressed the surface oh so carefully with fine waterpaper ... taking huge care not to get carborundum into the engine ....still not completely oil tight ....which is annoying !

I'm headed in high 30's temps in technical conditions in sand , it's gonna get TESTED .



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 02, 2012, 09:22:38 am
Glad you like the springs Veemax, they really lift the front nicely and the handling is sooo much better.

I haven't been riding mine much lately, I need to replace the steering bearings so I've left the old girl standing. Hopefully sort that out next week.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 02, 2012, 10:04:22 am
If only I had the space for a 9th bike ....

http://capetown-westerncape.gumtree.co.za/c-Cars-Vehicles-motorcycles-scooters-Suzuki-DR600-Dakar-W0QQAdIdZ359658852

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 02, 2012, 10:20:06 am
Nice bike.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 04, 2012, 11:11:55 am
WELL!!!! my tank is fixed , went for my first ride this morning! :biggrin:
Pipe is LOUD!!!! the bike is a changed machine after the rebuild, throttle response much improved, still a bit pap under 3000 rpm but pulls smoothly after that.

still have no headlight but indicators and brake light works.
Have not really whacked it open yet in top , but she is going well, just a few tweeks on the mixture screw and it will be dialed in , clutch is smooth as butter, no slipping (soaked plates for a week and a half before installing)

Just brakes, wheel bearings, spokes, crash bars etc and suspension to do......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 05, 2012, 09:36:35 am
Do you need crash bars on a DR? The only thing that is really vulnerable is the oil cooler.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 05, 2012, 10:55:07 am
Wow, what a weekend. Annoying brag pic for you guys with DR's still in the workshop  >:D
Here are my DR's Old and New doing service in a manner for which they are intended, my Old DR entrusted for the weekend to my mate Dave , who needed some bush and bike therapy.

Missed your call Volroom , due to being er ... kinda off grid.

(http://i971.photobucket.com/albums/ae199/Veemax/PairDRs.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 05, 2012, 01:01:09 pm
Were getting there WC! Less than two weeks from today for me. While I'm changing the tyres (put in some heavy duty RUBBER tubes (Heidi's) I checked the front fork springs free length. It was a bit mushy so was expecting thw worse-spending even more money on progressive springs. But..free length for both about 484mm while service limit is 462mm I think..put in some ATF-measured oil level like you suggested Veemax
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 05, 2012, 01:38:45 pm
Do you need crash bars on a DR? The only thing that is really vulnerable is the oil cooler.

I see on your profile pic that you've got crashbars on your DR DB9. I also want some, that magneto cover meets stone might leave you stranded in the middle of nowhere...no quick fix

I'm thinking as simple as possible - function over form. Some ideas?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 05, 2012, 03:46:09 pm
My cooler is now comfortably enfolded by the Acerbis tank, I want a heavy duty bash plate as my sump is vulnerable (I have a tin foily roady version) certainly want more crash protection for the motor , as brake lever, gear lever and casings are still vulnerable to a sharp rock, nothing to elaborate, something like the pic I posted earlier on the thread.

Lekker pic Veemax, Im envious , watch this space........
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 05, 2012, 04:25:36 pm
My cooler protector is MIA !

So I have a dik stuk square tube crudely welded to the frame , to take the punch in the event of a tip oppie klip !

My mate Dave dropped my DR in the sand , on the left.

The Sand got Velvaglo'ed .

( In the same way as when Chuck Norris swims ... Chuck Norris doesn't get wet. The water gets Chuck Norris )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 05, 2012, 04:58:13 pm
 :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 05, 2012, 06:18:26 pm
My DR krap die bosse , die bosse krap nie my DR nie

 :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 08:32:57 am
My cooler is now comfortably enfolded by the Acerbis tank, I want a heavy duty bash plate as my sump is vulnerable (I have a tin foily roady version) certainly want more crash protection for the motor , as brake lever, gear lever and casings are still vulnerable to a sharp rock, nothing to elaborate, something like the pic I posted earlier on the thread.

Lekker pic Veemax, Im envious , watch this space........

Sorry, I'm lazy - what page on this thread is the pic of the crashbars?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 06, 2012, 09:16:46 am
Here.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 09:58:00 am
thx...looks good. Problem of course is a pipe bender which I take it we don't have.
If we have this made up it'll cost a pretty penny..So what is plan of action?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 06, 2012, 10:32:17 am
Alternate plan, take bike to Groenie after you Dyno it.....
He makes up bars
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 10:52:16 am
Alternate plan, take bike to Groenie after you Dyno it.....
He makes up bars

aha! I like. Will try and find out EPOC (estimated price of crashbards)

do you know what you want to do with regards to the proper bashplate? LeCap supplies if I'm correct - price? Paying for crashbars makes me less want to pay for bashplate.

Welsh had a 6mm aluminium bash plate made up for his pig (R1150GS) at his work...helps if your in the engineering industry. Might try and make a plan
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 10:59:50 am
WC, you gonna check your spring fee length before you decide to get progressive springs? They might be OK still...

Veemax, what is the free length of your new progressive springs?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 11:09:16 am
Alternate plan, take bike to Groenie after you Dyno it.....
He makes up bars

Roughly R1000 says Groenie. He says that pipe should be bit thicker than that in picture to take the punch.
Keen?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 06, 2012, 12:08:18 pm

Veemax, what is the free length of your new progressive springs?


Ummmm, er.... don't know , but I ended up with the spacer's cut to 71mm before I was happy with the preload. There are no apples to compare with apples here , if you get my logic.

After having actually USED the bike on about 300km of gravel and technical offroad now, I can say it is a distinctive improved feel to the front end now , so maybe it's not KTM640Adv-like , but competent enough offroad to make me not care , and hey....no leaky USD seals and all that maintenance horseshit .... real BOOTS to keep Africa OUT of the working parts yes !

The Suzook may be a budget oldtimer but by riding it like you stole it , one gets huge satisfaction.

In the combination of rider + bike , I doubt if this venerable DR is the limiting factor for 90% of weekend adventurers out there.

I would not replace in-spec OEM springs with Progressive springs , just ride the thing, it works. I only chose Progressive coils because for whatever reason, my DR's factory units were really very, very moeg !



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 12:17:40 pm

Veemax, what is the free length of your new progressive springs?


Ummmm, er.... don't know , but I ended up with the spacer's cut to 71mm before I was happy with the preload. There are no apples to compare with apples here , if you get my logic.

After having actually USED the bike on about 300km of gravel and technical offroad now, I can say it is a distinctive improved feel to the front end now , so maybe it's not KTM640Adv-like , but competent enough offroad to make me not care , and hey....no leaky USD seals and all that maintenance horseshit .... real BOOTS to keep Africa OUT of the working parts yes !

The Suzook may be a budget oldtimer but by riding it like you stole it , one gets huge satisfaction.

In the combination of rider + bike , I doubt if this venerable DR is the limiting factor for 90% of weekend adventurers out there.

I would not replace in-spec OEM springs with Progressive springs , just ride the thing, it works. I only chose Progressive coils because for whatever reason, my DR's factory units were really very, very moeg !





Lekka. Yes, understand. Would you add some air to those forks to add some oemf?? 250kPa - 2.5 Bar (i think with hand pump...)
I know the okes say you don't have to -  but...the engineers thought of this when they designed the bike..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 06, 2012, 05:14:51 pm
Volroom, at the moment I'll stick it out and not ride anything 2 hardcore, I will be doing bars, serious bash plate and Wilburs on my front end (seals and oil 2) Before I go to Nam.
My build up to phase one is now complete, phase 2 is protection, shocks and wheel bearings, Phase 3  is a screen,lower gearing , new tires (rim locks etc) and Maaaaaaybe a little engine tweak

My motors running a bit rich, mixture screw 2 turns out, shall I flip a coin between turning screw in or bigger holes in the airbox?  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 06, 2012, 06:26:43 pm
My airbox and hole saw are also in imminent danger of meeting one another ! When you see what the new DR does with breathing, it adds to the impetus to get in there and boogie ....

I did say I'd have ONE standard bike in my stable though .... mmmmm....... stuff that huh !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 06, 2012, 06:47:55 pm
How much of the airbox did you chop on the new DR Veemax? Did you jet her up?
Air is thin up here  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 08:29:16 pm
Sjo WC - going all the way eh? What would you reckon she'd be costing you at the end of the day? I'm keeping my mods modest for now. Don't want to spend more than 5 grand on it.

I think I'll do the crashbars - if you also want to have them made up by Groenie, let me know and we can ask him to do 2 sets, maybe he'll give us a discount.. :peepwall:

There's very little of my airbox left...will post some pics later. I had this idea of some material that you could cover the holes with that still breaths but helps keep out the dust and..water. Walked in Mica the other day and saw this plastic sheets that'll breath. difficult to explain, let me take some pics. Don't know if it will help keep the airfilter cleaner a bit longer. Hopefully so

Veemax..chop up that airbox!! part of the human condition... I want to get some more out of the old DR. One of the reasons I'm having it dynoed.

Tell me, some dog under general technical says he repacks the exhaust packing every 2000km..!! What?! And now he want to replace with steel wool...

I recently packed my zorst and not doing it again soon for sure!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 06, 2012, 10:05:46 pm
check this skid/bash plate..nice

http://patwalshdesigns.com/Suzuki-Dr-650/Pat-Walsh-Skid-Plate-For-Suzuki-Dr650/26.html
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on March 07, 2012, 08:19:44 am
check this skid/bash plate..nice

http://patwalshdesigns.com/Suzuki-Dr-650/Pat-Walsh-Skid-Plate-For-Suzuki-Dr650/26.html

It's for the new DR

And if you think the Pat Walsh one is cool what about this one:

http://www.wilddog.za.net/forum/index.php?topic=36224.0



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 07, 2012, 11:26:33 am
That is a nice skidplate LeCap. Funds however is mimimal at the moment. So looking around to get some ideas. I might have a contact that can help me make one. Will try that - if not successful then I guess I'd have to fork out some dosh
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on March 07, 2012, 11:58:02 am
If you want somethng nice with lekker attachment brackets that absorbs an impact and not just some shite that clamps flush onto the frame tubes damaging the paint and not preventing the tubes from getting smashed you'll spend a lot of time and probably not much less money.

I didn't compromise much when I designed my bash plate since they were intended as a once off for my own bikes. Everything else I've seen is made more or less cheaply :-\
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 07, 2012, 03:33:17 pm
If you want somethng nice with lekker attachment brackets that absorbs an impact and not just some shite that clamps flush onto the frame tubes damaging the paint and not preventing the tubes from getting smashed you'll spend a lot of time and probably not much less money.

I didn't compromise much when I designed my bash plate since they were intended as a once off for my own bikes. Everything else I've seen is made more or less cheaply :-\

Will keep that in mind
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 07, 2012, 08:04:12 pm
how about a pre-96 Vintage Le Cap bash plate?  :3some:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on March 08, 2012, 07:56:47 am
how about a pre-96 Vintage Le Cap bash plate?  :3some:

How many are we talking about? If we can get an order of five together and someone who's going to drop off his bike for a day or three to measure & fit I'll make them :D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 09, 2012, 05:08:32 pm
Hi all ....okay first things first ...bash plate.....very happy with my huge OEM aluminium one , which is as tough as hell and probably overkill. If enough guys are serious I can assist Le Cap with the loan of my DR as a template.

VR ... I'll need a long story to describe the mods on my new DR induction ... not really the place for it here either.

Now to the business of my Oldtimer DR airbox though ....

OK , remember my starting point is a new, rebored, bone stock 1st oversize enjin , a new, re-sleeved, rebuilt bone stock BST carb, and stock header, stock airfilter, stock jets, and Scorch exhaust the only non factory item in the breathing chain.

Well , I just ran an experimental ride with the airbox cover off. Interesting. Firstly a typical intake honk as expected. HOONNNKKKKK ! : )

Starting and warmup felt the same. No issues on idle circuit, as expected.

A nasty lean flat spot comes in at 4500 rpm. Some surging at part throttle across mid rpm. Yup, it's LEAN like this. It revs out to 7000rpm with ease , but I suspect it runs very lean in the full-bore mode ... no missing as such, but the power fades off after 6000rpm.

Bottom line : Yes , the stock airbox is proven to be restrictive , yes, there is lattitude for improved performance.

It's going to require a tenacious application of patience to get the needle height correct for a classic Stage 2 airbox mod , and to select the main jet will require a proper dyno run , and I prefer to have Before AND After results ... validate scientifically any claims to increases power !

Big question is now ....do I VROETEL , or do I leave my healthy, happy, factory stock DR well alone !???

Dammit if only I could get 2-3 deg advance on the ignition .... that will awake some growl from that big piston.

Mmmmm , I think I need a beer , have an awesome weekend guys.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: grego on March 09, 2012, 07:28:34 pm
That is a nice skidplate LeCap. Funds however is mimimal at the moment. So looking around to get some ideas. I might have a contact that can help me make one. Will try that - if not successful then I guess I'd have to fork out some dosh
i just made a bash plate for my XR500.
if you can get one made, do it, don't worry about the cost!
unless you can get material for free and have someone who can do proper, neat welding for you, it will work out more expensive making it yourself!
spent nearly R1300 on mine now (material was pricey... 4mm marine grade alu) and its still not completely finished.
still needs a few welds and some holes with the hole saw.

the template alone took a good few days to perfect, and then still had to make brackets to fit it... lots of time lying under the bike sussing it out! kak job!
unless you have serious connections (bins of scrap alu and a professional welder at your disposal), you'll sukkel to make a proper, functional bash plate for cheaper than lecaps offering.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 09, 2012, 07:44:34 pm
Hi all ....okay first things first ...bash plate.....very happy with my huge OEM aluminium one , which is as tough as hell and probably overkill. If enough guys are serious I can assist Le Cap with the loan of my DR as a template.

Veemax, I understood the OEM bashplate is a bit flimsy...the one's me and WC have got on is stock and don't even cover the back end of the engine casing.

So, are you referring to the same bashplate we've got? Photo's perhaps?

Grego, I hear you. That's frieken crazy to pay that much for Al..I'll see what happens. thx
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: grego on March 09, 2012, 10:42:01 pm
Grego, I hear you. That's frieken crazy to pay that much for Al..I'll see what happens. thx
that was for the material as well as bending and welding.  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 10, 2012, 06:54:59 am
Yup, my bashplate does not even cover my sump assembly and it's really thin grade stuff , I need a seriaaaas one , but prob only after July when I get back from overseas.
In my eyes 1300 bucks is worth a hell of alot less than a big hole in a casing and an oil spill half my tank range from any civilisation  :mwink:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 10, 2012, 09:06:53 am
I've seen a 1400 Intruder and 650 'Strom both bust cases over rocks ... it aint pretty....engine hurri-kirri. Good night, nurse.

I'll take a pic of the thick and tenacious stock one and post it. Will absorb a meteor impact and shrug. Made in the day when men were men and BMW GS's were road bikes.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 10, 2012, 01:43:25 pm
Excuse the dirty, working, DR , not washed yet since it's last outing. ( Note the Khaki and the dust don't quite match, darn )

Herewith bash plate detail ,  a la Suzook Factory.

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5390.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5392.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5393.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5391.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5395.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 10, 2012, 01:48:17 pm
Mmm, note to self .... bash plate can also be used to drain spagetti , when in back country .

 :D :D :D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 10, 2012, 05:25:32 pm
 :imaposer: and braai chops, much like those squeeky clean spades found in Eskom techies bakkies.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 10, 2012, 05:31:00 pm
Why is that bashplate of yours different to ours Veemax? I think Suzuki did make alternative bashplate-seems you got it. Here's mines and WC's. That R 1800 for LeCap's Bashplate WC, not R1300.

I might have a problem..Suzukie Edenvale. They gace me wrong front sprocket. Got it replaced..after trying to fit the chaim today it seems they gave me another wrong one....

Look at the photo, in neutral I spun the back wheel with chain on-the chain every now and then wants to climb off the front sprocket. I'm thinking the new DR's takes 525 sprockets and chain, the Pre-96 take 520 chain and sprockets. Would a 525 front sprocket do that - as seen in the picture?

If this is the wrong front sprocket again...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 10, 2012, 05:45:29 pm
Best advice, go onto the Ron Ayers sight, check the microfische, get the part number

You up for a ride tomorrow Volroom, check out the planned rides, bring the pig if suzie aint ready.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 10, 2012, 06:03:02 pm
Enjoy the ride WC-tomorrow I've got boarding house duty the whole day. Will check out the site.thx. Can't wait to actually friekn ride the DR!!! Man! This is taking too long..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 11, 2012, 08:07:43 am
Why is that bashplate of yours different to ours Veemax? I think Suzuki did make alternative bashplate-seems you got it. Here's mines and WC's. That R 1800 for LeCap's Bashplate WC, not R1300.

I might have a problem..Suzukie Edenvale. They gace me wrong front sprocket. Got it replaced..after trying to fit the chaim today it seems they gave me another wrong one....

Look at the photo, in neutral I spun the back wheel with chain on-the chain every now and then wants to climb off the front sprocket. I'm thinking the new DR's takes 525 sprockets and chain, the Pre-96 take 520 chain and sprockets. Would a 525 front sprocket do that - as seen in the picture?

If this is the wrong front sprocket again...

I might add that I went from a 16 front sprocket to a 15...and had to even mod the retainer cap holes as it seems that they would only fit a 16 tooth font sprocket!! tel me please that somehow you can't change the 16 tooth front sprocket at all on the Dr!?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 11, 2012, 08:45:24 am
Screen sorted mcguyver style using door stops for spacers. Reason why I want space between existing front fairing and Dakar screen is to get the same effect that "tobinators" afford-less buffeting
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 11, 2012, 01:33:08 pm
I think pro-cycle offers a mod for different sprockets
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 11, 2012, 01:51:59 pm
I think pro-cycle offers a mod for different sprockets

Any comment on this...does it therfore mean that you can't friekn change the bloody front sprocket on the old DR's except with some mod!?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 11, 2012, 06:23:30 pm
I think it's more of a case of sprocket availability in our chain size, the mod changes your chain size, hence better front sprockets choice in new chain size

Keep the gearing as is, worked well in the dirt today.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 11, 2012, 06:29:24 pm
Did 200Km of mixed riding today, bike handled well on the fast dirt and slow technical stuff, consumption a bit high, not a tar road bike at all, slow and vibrates like hell!!!!!  :o

One for Veemax, us Vaalies also get out, on top of Breeds neck.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 12, 2012, 12:04:22 am
Aitsah !!! Nice to see it out and about , and lookin' PURTY and all . Is you side stand a bit short maybe ?  :-\

Whatcha call bad consumption then ? I'm almost never under 23km/L .... if your's is under 21 then maybe it's a problem?

VIBRATES ? Come come .... not ridden a KTM640 then ?  Or are you used to straight-six marine engines ???  ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 12, 2012, 10:41:17 am
I think it's more of a case of sprocket availability in our chain size, the mod changes your chain size, hence better front sprockets choice in new chain size

Keep the gearing as is, worked well in the dirt today.

I didn't mod anything really. The bike take 520 chain and sprockets, which I supposedly have. But for some reason the chain wants to come of the front sprocket. If the front sprocket is a 525, will it do that?

I wanted to change the gearing slightly because the the jerky nature ala BST40 at low revs. In town you can't always open up. So wanted to get the revs up a bit and opted for 1 tooth less than stock front sprocket: 15

I need to know what's wrong so I can AGAIN go to Suzuki..do I have a 525 front sprocket instead of a 520 perhaps?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 12, 2012, 06:19:24 pm
UUUUUUM! try about 13 to the liter  :peepwall: lifted the clip on the needle today to lean her up a bit , but she had no legs over 120 on the ride  :-\
Thinking of going back to stock needle and jetting  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Hagar on March 12, 2012, 06:42:30 pm
Volroom, although the 520 and 525 share the same pitch, (length of chain link and roller diameter is the same)

However the with of the rollers differ.  Inner with on the 520 is  1/4"  6.35mm.   On the 525 it  is 5/16"  almost 8mm.  I do not know how much the actual thickness of the sprockets differ.  I guess that differs a bit from brand to brand.  Might be your problem.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 12, 2012, 07:42:20 pm
Volroom, although the 520 and 525 share the same pitch, (length of chain link and roller diameter is the same)

However the with of the rollers differ.  Inner with on the 520 is  1/4"  6.35mm.   On the 525 it  is 5/16"  almost 8mm.  I do not know how much the actual thickness of the sprockets differ.  I guess that differs a bit from brand to brand.  Might be your problem.

Thx Hagar..but would a different width cause what I'm seeing: the chain wants to come of periodically on the front sprocket - that means that the teeth does not go in where it should at the chain, a tooth would actually be in between the rollers..if you look at the photo you'd see what happens periodically. I don't know..phoned Suzuki. might be taking the new sprocket back again...

Question: can you change the front sprocket on the old DR's? The retainer plate which is held by those three bolts (that holds the front sprocket on the splines) seems to indicate that your stuck with a 16 tooth front sprocket...has anyone changed to smaller front sprocket? Man...murphy you bleddie bliksem!!!!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 12, 2012, 07:57:15 pm
gearing won't cure surging, play with carb, my bike hardly surges now even in first gear slow rocky stuff, just chows juice and makes soot like a chooka train  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 12, 2012, 08:13:14 pm
Ron Ayers sight  -  no info on front sprockets!! no one had such an issue before?

I bought this plastic net material.. I'm thinking of gluing it over airfilter hole..that's HOLE. Idea is to act a some kind of filter for big particles..does this make sense? Any comments?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 12, 2012, 08:13:15 pm
If you rjetting is right the bike shouldn't surge. Mine doesn't. An the cure for chugging under 3000rpm is a 47 rear sprocket!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 12, 2012, 08:22:51 pm
If you rjetting is right the bike shouldn't surge. Mine doesn't. An the cure for chugging under 3000rpm is a 47 rear sprocket!

Thought I'd sort it out going smaller on front sprocket - same affect. One tooth less than stock front sprocket same us upping rear with three teeth. They also told me that 42 tooth rear was biggest rear sprocket avail...sometime I wish I lived in first word country..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 13, 2012, 08:17:01 am
Ahem. My STOCK bike with STOCK chain and STOCK carb does not surge. When you mod an airbox you lose positive crankcase ventilation , and you affect the vacuum ... ever so slightly....on the upside of the carb diaphragm .... these two properties balance the fine control of the slide at part throttle .... now add a worn slide with air getting past under conditions of high engine vacuum .... what do you have ? Erratic lean behaviour and surging. With an open airbox you have to invest considerable time tweaking the needle height to try to overcome the new set of conditions existing in the fine control of the fuel/air stochiometry. It's not for the faint hearted !

Over-rich ( a la WC @ 13km/L ) will certainly overcome surging ! The trick is to get it Right. This means 10 to 20 times fuel tank removal playing with washers and shims and needles until you get it right. It's wise to get everything else in order first....float height, idle screw, any worn parts like needle/nozzle/slide etc and be bloody sure your valves are spot on.

Sorry I can't help with the chain issue, I always shop with the old part in hand as a rule, so that way when I walk out with a replacement it looks like the one that works !

I had a mesh on my very open KTM640 airbox to keep chunks out , held in place by hotmelt glue ( on roughened plastic ).

On my new DR I have removed the snorkel and made one round additional hole on top , no screen ... and the main jet was upped from a 140 to 150 and the needle height is std. This leads to a very slightly lean condition at mid-throttle on a cold day at the coast, but as soon as the day warms up or I head inland and UP, it comes bang into the zone, and I get 23 even 25 km / L on the new DR.

Funny the old DR runs a smaller main jet .... I guess this is because the valve overlap and therefore open-duration of the SUCK phase, is longer due to the cam ... meaning there is more air volume going through the engine at a given RPM, and therefore more TIME for fuel to atomise from the nozzle...

What I learned with my Old DR project, is that the needle/nozzle wear condition is really the Hinge Factor in any attempt to set up the carb properly. In theory the needle/nozzle clearance should only affect tuning over 1/3rd throttle position, but I found the blerrie thing affects the whole BAND of throttle conditions.

My advice : Replace these parts with NEW, set the floats to spec, get the engine hot and get the idle circuit right ... then if you have a modified airbox, get to work on trying to get the needle height right. If it surges it's lean , if it makes soot its rich, if it behaves erratically all over the show and you can't win .... ( as in my case ) .... get onto Motolab and buy a new slide and new slide guide....and like magic, your oldtimer thumper will ride like the day it came out the factory !!! : ) : )

I've pondered this airbox question. My bike goes like SNOT , I see 170-175 kph with ease. I'm gonna leave it all alone, and if I want to go fast, I have 1200cc's of Stage 2 fury that embarrases italian sports bikes that cost for times as much  :ricky:

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 13, 2012, 09:22:53 am
wow..technical stuff there Veemax. I'm off to the dyno rather
Have heard that newly packed packing in zorst needs to bed over couple of 100km's at lowish revs otherwise if you wack it it can damage packing. So before I go dyno, I will do some mileage at low revs - that's if I can get my bloody front sprocket right.

How do you know that the engine is running lean VM? I've got no idea if it's lean and don't want to damage engine. Besides surging is there some way to tell? What are the circumstance when you burn a valve? Obviously I want to avoid that

Thx, I will then fit that net over airbox HOLE.

Cheers
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 13, 2012, 11:31:17 am
Lean clues as follows:-

1) Loss of power
2) Surging ! Particularly under no-load or light-load conditions
3) Needs choke much longer, and more choke .. cold blooded, slowly slowly gets better as engine and engine oil warms up
4) Detonation, pinking
5) Rides horrible when cold and during warm-up
6) Performs better all round only with engine piping hot
7) White / Light spark plug
8) Light colour exhaust ( white in the old days of lead ) , or 'orange .' hue with LRP
9) Bluing of chrome headers
10) If you are In Tune with engines, you can almost "feel" the flame-front inside the engine burns faster, closer to a Bang than a Burn.
11) Very good fuel consumption !
12) Burnt valves or melted piston crowns ( extreme ! )
13) At full throttle, high speed,  if you roll off slightly , it picks up !
14) The Lamda censor on the dyno is above the ideal line ! Hhahahahahahahahhahaaaaahahaaaa

Of course the question of LEAN or RICH applies differentially to load, throttle position, engine RPM, ambient temp, alititude, barometric pressure, which blerrie circuit in the carb you are addressing, everything.

I tune for precise mixture at full throttle ( for power ) , slight lean on mid throttle for economy and hot / high conditions, and slightly rich at idle for quick warm-up and to prevent coughing off during the first phase of riding from a cold engine.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 13, 2012, 09:14:40 pm
Wow, that's a lot to take in. I just want to avoid burnt valves as much as possible. So, loss of power - surging (giving throttle only to find a delayed power delivery) would be the main ones to look for..

You know a lot about bikes. Yah, why not - keep your DR as is. If you need to feel the power you have other bikes to do that on...come to think of of it, so do I...

But..everyone to his own devices!  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 15, 2012, 07:32:09 am
Update: figured out why the chain was wanting to come off the front sprocket. There was a rubber flat O-ring (to dampen the noise it seems) between the retainer plate and the front sprocket. Going one tooth less in front meant I had to decrease size of that O-ring otherwise it would do exactly that: push the chain off the sprocket every half cycle. So, gonna make some O-rings myself


Note should you want to change front sprocket size on old DR. the retainer plate needs to be modified as well as the O-ring
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 15, 2012, 08:01:09 am
Science prevails huh !!! Well sorted !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 15, 2012, 08:06:05 am
I have in my hand , Locktite 5699 , heat resistant to 329 deg C , come here brand new little leaky oil return pipe O-ring , get past THIS !!!!

Damn, this stupid joint is basically just a poor design ... I can find no flaw in the metal surfaces , nothing skew, nothing rough, nothing out of place ....

" improved adhesion to oily surfaces and three times more oil resistamt than generic silicones " it says.

Third time lucky ???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 16, 2012, 07:03:26 am
VM, you once said that the old DR got a 150W generator, that would provide 12.5amps of current (probably at something like 4000 revs or something). My compressor pulls 10amps. Want to fit cigarette lighter unit to the DR so I can inflate when I've deflated or when I fix a puncture.

Where did you read 150W? I went through the manual - don't see anything? (the gs got a 700W alternator)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 16, 2012, 07:43:17 am
Hey Volroom ! Workshop manual Chapter 8 under detailed specs you will find 150W for '93 and 200W for '94+'95 , it's in there !

A pomp is a pomp ou pal , every man needs a good pomp , even a bad pomp is better than no pomp at all.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 16, 2012, 10:38:33 am
Hey Volroom ! Workshop manual Chapter 8 under detailed specs you will find 150W for '93 and 200W for '94+'95 , it's in there !

A pomp is a pomp ou pal , every man needs a good pomp , even a bad pomp is better than no pomp at all.

haha! thx, seems I don't have in the manual I've got. You can't perhaps send me that one you've got? that's great, will get the cigarette lighter socket connected to the battery soon and show pics. Good if you want specific pressure in tyres when doing technical. can't wait....
dyno postponed again until next week..so the week after that
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 17, 2012, 11:14:38 am
Locktite 5699 is THE Gasket maker. Hooray, I have FINALLY beaten that oil return pipe weep. You really just wet the surfaces with the stuff , use it in place of grease to lube things up to shove it in ... if you know what I mean.

( Use excess silicone at your PERIL ... and also.....have the discipline to not touch the bike until full cure ....just in case you pushed up a blob inside... you don't want this stuff moving around inside an engine )

YAYYY , I have honestly nothing left to do on my bike now , except ride it. I'll be a while before I wear out the front pads , at which time I'll install new pads and my new disk rotor together.

The more you ride this bike, the more it grows on you. It's temperament is not suited to chugging in traffic , it's only downfall , but if you adapt and keep the mill spinning free at 3000 rpm and your carb is on the money, it's really not a problem.

It sure likes to be worked hard , it ain't no XT 500 , this is a bike for open roads and spirited riding. Being a low-value, tenacious, battle tested machine ... ride it like you STOLE it !

Now come come , lets see if you can get yours ready, come Spring it'll be great to have a gathering !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 18, 2012, 06:30:39 am
How about a test run on 31 March Volroom?

Yeah Veemax my stand seems short or maybe my bike just has the shocks jacked up to the max, however I like the angle of heel it enhances stability when parked to windward  :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 18, 2012, 09:33:54 am
A Diabolical luggage system is forming in my mind ....105mm PVC pipe..... it / they will look like the smoke launchers on a Ratel .... light weight, very durable , and unlike any luggage system, you screw the cap on .... ha, 6 bar pressure ! Ubiquitous parts catalog from the local plumbing supplies ...and no sharp corners to break your bones .... mmmmm .......thinks......
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 18, 2012, 01:07:36 pm
Would like to see that luggage VM! I bought an ATG bag from Michnus but might not be enough for week long trip...31 March!! yes!! I will be finished!!

Great things comes to those who wait..

Next week dyno. Chain sorted, putting on wheels today, sprockets and chain are on. Screen going on today. I'm about to talk to Groenie about the crashbars, bashplate and handle bar raisers..haha
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 18, 2012, 05:13:29 pm
My namib rig will be a "goose tube" where my other pipe went, for tools , a small US army "bum bag" strapped to my carrier rack with spare tubes and emergency walk out kit, roll bag with tent, sleeping bag etc on top of that  and a set of small soft panniers for other stuff, plus a 5L Jerry can for water, over and above my hydration packs 2L with my rain gear in it as well and my 1L water bottle.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 19, 2012, 09:22:54 am
Aaarggghhhh!! that sounds Awesome WC. Would love to go on such en excursion. Got compact tent, might need to look into  a more compact sleeping bag though, i'd take along jerry can with 5L of fuel as I don't have a moerse tank like yours. Got first aid kit (small one), hydration pack (3L), will be fitting my Goose tube soon, got extra tubes and puncture kit

To date: screen fitted (had to modify screen slightly for indicators - take note when buying dakar screen), fork legs got new oil, headlight got OSRAM nightbreaker plus bulb (much better..), new proper oil, sparkplugs, air filter element, valve clearance set, balancer chain adjusted, zorst got new packing - packed to the brim, exhaust not leaking anymore thx to gasket and gumgum, New tyres (Mitas E09 and T63) and heavy duty Heidi tubeson, new sprockets and DID VX chain on, fitted net material over a moerse gaping hole in the airbox (I made it bigger than shown before), might be getting hand guards soon (Zeta), will be getting crashbars, bashplate and handle bar raisers as well and I think that ..is that..sometime this week it'll be dynoed - it is running lean I think, having increased the size of the airbox hole greatly, getting moerse hot..might also look into DIY LED spots soon. Fitting a cigarette lighter socket for compressor this week also.

Need to get it to the dyno in centurion this week.I won't stand a chance of burning valves? till what throttle opening does idling jet play a role? Cause we decreases the size of the indling jet significantly, but increased size of main jet, and slightly changed needle setting to more rich also
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 19, 2012, 09:37:34 am
Hey Volroom when you put it all together , you've been a very busy guy ! Sounds brilliant. Dammit that deal you got is amazing.

An open airbox won't affect the idle circuit, no worries there. My guess is that you will end up with a much raised jet needle, and a main jet in the order of a 150.

Do yourself a favour , for part throttle mixture , try to get it exact up there at altitude, my reasoning is thus: It will be a little lean at lower altitude. Thumpers wear needles. It will therefore wear IN , and not so much wear OUT ! Most rides you do will be DOWN from where you live, right ?

I'm here at sea level, so I set max lean I can get away with. My logic is opposite. When I head off on a ride, I'm heading UP !

So also, my carb setting is set to wear IN and not OUT ! When I leave the city and head inland my bike comes into The Zone.

There is something satisfying about knowing your bike will get healthier as it beds down, or goes off on an adventure...

Or maybe I just over think sh^t , and should, like, duuuuude, chill OUT man !  :drunken_smilie:



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 19, 2012, 09:47:19 am
Thx VM, so getting what your saying, I should get it spot on so that when heading off closer to sea level the engine would run a little lean purely for the preservation of needle? running slightly leaner won't be problem would it? just better mileage.. :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 19, 2012, 01:25:06 pm
Uh oh , I'd better be careful what I post now. There is this newbie member Goshawk stalking me.  :peepwall:

You gotta watch out for these females ...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 19, 2012, 03:26:33 pm
my front suspension still a big soggy. Not very bad, but would like it slightly stiffer.
I've asked before, the manual says you can give the front forks some pressure: 2.5bar.
has anyone done this?Thinking that the engineers must have thought of something when they made the front suspension as they did. I'd guess when the springs starts to lose free length, you can compensate with pressurized air?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 19, 2012, 03:43:22 pm
Haven't used pressure in forks for 1000 years, or so it seems ... it's too darn finnicky. Are you sure it's SAG that you're wanting to correct ?

If it's under damped , simply concoct a higher viscosity fork oil ....

Suspension tuning is a tricky thing , but there are basic rules of thumb. The starting point is the correct spring preload ... the normal starting point for forks is one-third travel in sag with a full gas tank and your good self on board....

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 19, 2012, 04:25:56 pm
Hmmm. interesting. I added ATF for fork oil. Don't know how the weight compares. What fork oil would be more dense? can you recommend?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 19, 2012, 05:06:30 pm
Now you are playing to my core competence as a retired inkmaker : ) , I used to ( sadly past tense ) have access to very advanced viscometry equipment ...

ATF is very thin , little wonder your bike feels bouncy .... spec is for SAE10W.....

Try straight 10W pukka fork oil before doing anything else ?

You can blend 10 W with 15 W , even use gear + fork oil blends if you need to get really serious !

There are oils and oils, without advanced equipment to test them , you can be all over the place within the SAME so-called rating.

I found one manufactures 5 is thicker than another 10 !

But foam and temperature in the real world changes everything in the dynamic environment of a motorcycle.

One crude way to measure viscosity is via efflux time through a flow cup, such as a Zahn or Shell cup, but that is special lab equipment, so alternatively you can make a crude flow cup from an upside down bottle with a hole in the lid and a stopwatch.  At least in a crude way you can quantify with some degree of science whether an oil is thicker or thinner than another.

ATF makes good fork oil , but it's not the best solution in the modern world of specialised designed oils , nor is it likely going to behave like a purpose formulated 10W .... especially in an offroad application!



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 19, 2012, 07:34:35 pm
Agreed, gooi 10w like the manual says, you in for a 200k test ride Volroom? 31st of March
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 19, 2012, 07:40:53 pm
Agreed, gooi 10w like the manual says, you in for a 200k test ride Volroom? 31st of March

I'll likely come a join you on that Breedt's nek ride.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 19, 2012, 07:43:20 pm
Marvelous DB9 now we need Volrooms boney for a full pre-96 turnout, ooooops Superdave you in?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 19, 2012, 07:58:05 pm
Cool, I'm keen to see that pimped DR of yours in the flesh!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 19, 2012, 08:02:42 pm
 :thumleft: as am I to see your original legend
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 19, 2012, 08:42:09 pm
I wish I could join. Really. Really.

But I can't. I am waiting for a gasket set already forever, and my ...

Pro-Cycle parts are also finding their way to me. Decided against going for 100mm bore as having looked closely at the head there is simply not enough meat to go up 5mm in dia.

So I ordered some nice goodies including the Wiseco 97mm piston.

When parts arrive will have them Power Koted i.e. barrel, piston top, combustion chamber including valves and springs, exhaust, and tappet covers. The exhaust system 3mm larger if possible and balanced crank.Possibly a larger oil cooler will also do service.

The head will be modded to big valve head i.e. 32mm and 36mm valves with reprofiled cam. Some flowing of the head as well.

Dynotuned BST40 carb with slide mod and we will have a very nice spread of torque for the bike and  that can run at high revs without any risk of overheating.

So I hope by end of April we will be up and running.

Now - to say a prayer and ask for some help here is probably the right thing to do at this point. LOL

 :thumleft: :thumleft:


Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 19, 2012, 09:19:02 pm
I will know tomorrow morning , if I am coming to Vaalie Land. I am in the procurement process again ... pretty unexciting V twin to kick back on to ride with the Missus ...  ( who is now on this Forum as Goshawk.....when in DualSport mode on her XLX350R....)

Anyway , some of the best rides I have done in life, have been with mates on similar hardware, so if I have to suck it up on an 805cc Cruiser to ride tar with the wife, so be it.

If this Benoni Bike comes together , it would be great to meet you guys for a beer, and make larger, more elaborate plans for later this year, for an Ole DR gathering ?!

If any of you volunteer to ride an 800cc Marauder down to CT , let me know : ) : ) ..... I might be an ou ballie turning 50, but I can suck up kilometers as good as any of yer !



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 19, 2012, 10:38:30 pm
Yeah, I'm in but can only pitch at 12pm..buisy in morning, sunday can also work?
10W..what about mixing it with gear oil? Got some 80w90. What would the ratio be? I'm thinking take fork legs out, pour out as much oil as will come out and measure quantity. Then, put same volume back but mixed

Good idea?bad idea?

Superdave, that boney you are buisy with sounds awesome..strongs for the process
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 20, 2012, 06:26:01 am
Put the exact amount as the manual tells you in your forks Volroom.
Go and buy some 10W, suspension is prob the most important thing on a bike so don't skimp on it  :biggrin:

Superdave, what gaskets are you waiting for? You can prob make up all gaskets besides the head and base gaskets.
I wanna see how your DR runs after those mods, she should be a flyer  :ricky:
What valves will you be using? Sounds interesting  :mwink:

Veemax, are you spending a few days up here?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 20, 2012, 08:27:12 am
SuperDave ! Your SuperDR camshaft reprofile ... will of course change the nature of the beast in it's entirety. Do tell us more ... what profile will you choose ? Benchmark from another enjin ? Concoct by rule-of-Dave your own open/close/lift/duration curve ? This is fascinating ... have you an engineering firm in mind already able to anneal, regrind, reharden etc ?

Bigger everything with better heat conduction and more compression is going to do great things , but the cam will dictate the persona won't it ?

Years ago I soooooped up an XT500 with Wiseco pooftin , hot cam et al , I went with a bigger header .... was a disaster.....I recall someone giving me a fat lecture on Exhaust Velocity ..... have you seen the skinny headers on superbikes these days ? I'm just sayin' .... beware this variable does not work backwards on yer ... exhaust design is a tricky thing, maybe a stepped header or a careful logical approach with a Before and After factored in, might serve you well. Just sharing and caring here : )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 20, 2012, 08:58:12 am
@veemax - cam shaft profile is Pro Cycle 190. I have all the specs and durations and overlaps and , and, ...
Been proven by Procycle so if the cam engineer knows what he is doing we have a winner.

As for the slightly larger header pipe - Iam not sur eyet of the effect of the gas velocity and will be doing some calculations with a fundi on this. We will still decide on this.

As for the bigger valves - its no bigger than the Honda XR650, KLR650. In fact it is a little small for the bike and this should relase some volume of gasandhence the possible size increase on header. More volume in thin pipe will speed up velocity but it may also restrict it. The fundi's will know better.

Now the ride to Breds Nek 3121 March 2012 - I was contemplating the Honda XRV750R but it has no protection bars and if I should drop it(it weighs like 220kg), gonna damage this collectors item and there are precious little if any parts around.

Maybe take it vewry slowly - but still no guarantees of not slipping or falling.

So then perhaps the wife's Aprillia Pegaso - but the tires are Kenda on rear and if there is any hint of water it will be like riding on an ice rink.

Dunno- decisions decisions
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 20, 2012, 03:56:55 pm
Now you are playing to my core competence as a retired inkmaker : ) , I used to ( sadly past tense ) have access to very advanced viscometry equipment ...

ATF is very thin , little wonder your bike feels bouncy .... spec is for SAE10W.....

Try straight 10W pukka fork oil before doing anything else ?

You can blend 10 W with 15 W , even use gear + fork oil blends if you need to get really serious !

There are oils and oils, without advanced equipment to test them , you can be all over the place within the SAME so-called rating.

I found one manufactures 5 is thicker than another 10 !

But foam and temperature in the real world changes everything in the dynamic environment of a motorcycle.

One crude way to measure viscosity is via efflux time through a flow cup, such as a Zahn or Shell cup, but that is special lab equipment, so alternatively you can make a crude flow cup from an upside down bottle with a hole in the lid and a stopwatch.  At least in a crude way you can quantify with some degree of science whether an oil is thicker or thinner than another.

ATF makes good fork oil , but it's not the best solution in the modern world of specialised designed oils , nor is it likely going to behave like a purpose formulated 10W .... especially in an offroad application!


I was on my way to buy proper fork oil when I heard from another dog to simply use ATF. I have used ATF before on my HONDA XL500R. So, I did and now I wish I did different since the ATF cost me about the same as Motul fork oil. Thing is that the motul is R110 per litre, I need 1.1L. Buying two bottles because you need an extra 100ml...

Veemax, you say mixing gear oil with Fork oil is an option. Well then, if I mix some gear oil with the ATF won't it help?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 20, 2012, 05:05:40 pm
By some miracle I have a printout of a R0.5 million Haake viscometer under linear shear mode,  in my hand of some value to this fork oil discussion, I just happened to be tidying out my study !!! Sjoe, I retired > 2 years ago, and have this right here ...weird !

Here is some hard data:

Gabriel Red oil                20 cP
Castrol AWS 10              22 cP
KTM OEM WP                   39cP
IGT Shocks 25% Gearbox Oil / 75% Garbriel Red   43 cP
Putoline HPX5                  44cP   
Castol SAE 10 W Fork Oil  67 cP
IGT Shocks 50% Gearbox Oil    85 cP

I dunno what to advise you VR , because I have no datum for ATF ... but it looks like as a starting point you could blend about 33% Gearbox Oil with 67 % ATF and come within 44 to 67 cP ????

If it's overdamped just let it down with more ATF until you hit FRTM * point , or vice versa.

Gearbox oil is designed not to foam , and handle high shear , same condition as inside suspension, so it makes sense.

Hope this helps.

I am flying to Jhb arriving 12pm Thursday , paying a guy for a bike, and heading out on it towards Potch right away , no chance to see you ... unless you can provide dancing girls , infinite booze, and a four poster feather bed for the night.

I have to outrun the holiday crown headed for CT , who will be doing their best to overtake me on Friday.

* Feels Right To Me





       
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 20, 2012, 05:44:12 pm
Stefan Hessler racing, the DR guru from Germany advertises headers that are 3mm bigger than stock if I remember correctly
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 20, 2012, 05:50:00 pm
@veemax - cam shaft profile is Pro Cycle 190. I have all the specs and durations and overlaps and , and, ...
Been proven by Procycle so if the cam engineer knows what he is doing we have a winner.

As for the slightly larger header pipe - Iam not sur eyet of the effect of the gas velocity and will be doing some calculations with a fundi on this. We will still decide on this.

As for the bigger valves - its no bigger than the Honda XR650, KLR650. In fact it is a little small for the bike and this should relase some volume of gasandhence the possible size increase on header. More volume in thin pipe will speed up velocity but it may also restrict it. The fundi's will know better.

Now the ride to Breds Nek 3121 March 2012 - I was contemplating the Honda XRV750R but it has no protection bars and if I should drop it(it weighs like 220kg), gonna damage this collectors item and there are precious little if any parts around.

Maybe take it vewry slowly - but still no guarantees of not slipping or falling.

So then perhaps the wife's Aprillia Pegaso - but the tires are Kenda on rear and if there is any hint of water it will be like riding on an ice rink.

Dunno- decisions decisions

Its easy enough to get up breedt's nek. Its just a bit tricky to go down the north side in a car, bike is a piece of piss.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 20, 2012, 09:23:03 pm
By some miracle I have a printout of a R0.5 million Haake viscometer under linear shear mode,  in my hand of some value to this fork oil discussion, I just happened to be tidying out my study !!! Sjoe, I retired > 2 years ago, and have this right here ...weird !

Here is some hard data:

Gabriel Red oil                20 cP
Castrol AWS 10              22 cP
KTM OEM WP                   39cP
IGT Shocks 25% Gearbox Oil / 75% Garbriel Red   43 cP
Putoline HPX5                  44cP   
Castol SAE 10 W Fork Oil  67 cP
IGT Shocks 50% Gearbox Oil    85 cP

I dunno what to advise you VR , because I have no datum for ATF ... but it looks like as a starting point you could blend about 33% Gearbox Oil with 67 % ATF and come within 44 to 67 cP ????

If it's overdamped just let it down with more ATF until you hit FRTM * point , or vice versa.

Gearbox oil is designed not to foam , and handle high shear , same condition as inside suspension, so it makes sense.

Hope this helps.

I am flying to Jhb arriving 12pm Thursday , paying a guy for a bike, and heading out on it towards Potch right away , no chance to see you ... unless you can provide dancing girls , infinite booze, and a four poster feather bed for the night.

I have to outrun the holiday crown headed for CT , who will be doing their best to overtake me on Friday.

* Feels Right To Me
     

Thx VM. Had a look at the oils out there. Guy at bikeshop in Edenvale says that changing the preload can help. Even though the spring fee length is still good, when I push the front down..it goes way down almost bottoming out. Not supposed to happen. So...changing the oil to a heavier weight would make the forks compress SLOWER, but the sag when loaded with full tank would be exactly the same. Changing the preload would change that. And when the springs do eventually die..I'll get new ones.

I'll use Motul 10W oil with the preload adjusted  - will get the right diameter PVC pipe.  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 20, 2012, 09:26:12 pm
BTW, the 1 tooth less front sprocket is working great for the jerkiness at slow speed. 5000rpm at 100km/h. On gravel that seems right doesn't it? Engine provide max torque at cruising speed. Really does feel better. will update about fuel economy
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 21, 2012, 07:04:47 am
BTW, the 1 tooth less front sprocket is working great for the jerkiness at slow speed. 5000rpm at 100km/h. On gravel that seems right doesn't it? Engine provide max torque at cruising speed. Really does feel better. will update about fuel economy

I have a 47 rear and it give me slightly longer legs than that, 5000rpm is about 107kph. What rear tyre are you using? The D606 I have is slightly larger diameter than a 50/50 type tyre.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 21, 2012, 07:52:27 am
DB9, I used gear gearingcommander to check things out beforehand. Rear tyre Mitas E09 130/70/17. Put in specs of your rear tyre, sprocket sizes and it will tell you exactly what speeds you can do at whichever revs. Changing the front sprocket did bring down max speeds some 10km/h which I don't mind.

Now, when I'm cruising and I open throttle it picks up nicely and when at slow speed it's more smooth - technical riding might benefit

http://www.gearingcommander.com/
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 21, 2012, 08:17:09 am
Something wrong with gearing commander's calcs it seems. Stock is stock, Current is my setup, Custom is your setup. RPM at 120kph
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 21, 2012, 08:21:40 am
Think I should go count the teeth on my sprockets  :-\
Bike has no legs over 120
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 21, 2012, 08:26:10 am
When mine had the stock gearing it ran quite nicely up to 150. Now it tops out at about 135-140, but it gets there very quickly. I cruise at about 105-110 usually which is around 5000rpm. I use the DR for dirt just aout exclusively, so I have no need to go over 120.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 21, 2012, 09:11:27 am
My gearing stays stock ... for this ....

(http://i971.photobucket.com/albums/ae199/Veemax/WestNam.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 21, 2012, 09:16:46 am
My gearing stays stock ... for this ....

(http://i971.photobucket.com/albums/ae199/Veemax/WestNam.jpg)


Lucky bastard.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 21, 2012, 09:22:54 am
Watch out for those sandy patches at hell for leather pace  >:D
Cool pic
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 21, 2012, 09:23:54 am
And a bit of thisssss

( Point is .... horizons can be far, and I don't want over gearing .... guys riding with me, same bike,  with -1 tooth have returned 20% less fuel range .... passop , is all I say !

(http://i971.photobucket.com/albums/ae199/Veemax/WestNam2.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 21, 2012, 09:26:58 am
Watch out for those sandy patches at hell for leather pace  >:D
Cool pic

After the twentieth stofgat at 190 + , you eventually stock karking yourself ! ( KTM950 ) ..... MOMENTUM IS YOUR FRIEND !  >:D >:D >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 21, 2012, 09:30:31 am
+1 , noted all I need is 11 to the liter  :biggrin:
Consumption has improved though, time to raise the needle clip to it's top and final notch I guess.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 21, 2012, 09:30:54 am
Proof that sand demons can be overcome , after 140 km of this stuff .... again, stock gearing rocks !

And the DR is lighter than this KTM 950 ( I'm getting old ! )

(http://i971.photobucket.com/albums/ae199/Veemax/SandDemons.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 21, 2012, 09:33:39 am
I actually just remembered I changed my sprockets and chain before the re-build, got rear sprocket and chain for a bottle of brandy from a mate, I must check, never did a long ride since then, maybe my gearing is FUBAR  :deal:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 21, 2012, 09:34:07 am
Ok, I'll stop posting teaser pics ????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 21, 2012, 09:48:35 am
16/42  ???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 21, 2012, 09:50:38 am
16-42 is standard
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 21, 2012, 01:29:17 pm
ok, we'll see what the fuel consumption is eventually but otherwise very happy with gearing. I'm not keen for more than 120km/h on dirt, want to keep to that rule no matter if it's a dirt highway - when going fast also not easy appreciating the scenery.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 21, 2012, 06:11:46 pm
Have to say VM, those are awesome pics..wow. One day when I'm back in the Cape, I'll also explore the karoo's
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 25, 2012, 12:04:41 pm
Saturday morn coming has opened up, so I'm in. WC, is it going to be a hardcore technical ride? I won't yet have crashbars and bashplate on by Sat. Cool if we take is slowly? I'm still a noob in a sense when it comes to gravel
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 26, 2012, 11:27:53 am
It is sat or sunday, check the planning a ride dualies to breeds neck thread, it's gravel and some 1st gear up the rock hill and down the other side stuff , pretty easy I did it a few weeks back.
Always take it slow I do.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 27, 2012, 08:50:32 am
Great stuff. will check it out.

UPdate on the dyno. So yesterday I rock up at Charlie's place and we can't find the dyno kit, then we eventually get it. As we try to get the probe in the zorst there's an obstruction..the okes that made up the zorst decided to weld a plate in the middle to make it nice and quite it seems...Can't get the probe in deep enough..so, I'm gonna take a frieken welding rod and make a hole in it. Charlie says that an entirely open pipe is extremely loud, to the point where it's not a good thing anymore.

Wan't to try and avoid making the hole too big then, but..that obstruction is affecting the performance in a bad way. There's a leak as well on the zorst that I have to sort out again..

If all goes well I'll have the bike dynoed by Thursday. Also connecting cigarette lighter socket. Can I sommer connect the negative to any metal on the bike? Live goes on pos of battery, negative (earth) anywhere?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on March 27, 2012, 09:42:35 am
IMHO the best solution for a bike which at some stage will need a dyno tune is to use a threaded probe into the manifold / header pipe.
Very easy & cheap to weld in the threaded bit to take the probe, the probe is where you want it and once you're oune you just plug it up ready to bve used again whenever necessary.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 27, 2012, 11:20:49 am
@Le Cap -where would you position it on the header? And what size hole should it be?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 28, 2012, 07:24:30 am
 Also connecting cigarette lighter socket. Can I sommer connect the negative to any metal on the bike? Live goes on pos of battery, negative (earth) anywhere?


Another questions, what is maxium voltage battery provides while charging, while riding at say highway speeds?
If I fit LED spots, I need to know.
Thx
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on March 28, 2012, 08:53:00 am
Always connect ground to battery negative terminal. Else you end up with Italian electrics ::)

14.5 - 14.8V max
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 28, 2012, 10:32:14 am
Always connect ground to battery negative terminal. Else you end up with Italian electrics ::)

14.5 - 14.8V max

Hmmm. thx. that's for a brand new battery I guess, right - at max revs, right? I need it to be no more than 14.4V - will it be that at lower revs?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 28, 2012, 10:40:20 am
Agreed, gooi 10w like the manual says, you in for a 200k test ride Volroom? 31st of March

I'll likely come a join you on that Breedt's nek ride.

Are you two still going on this ride? Which day?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 28, 2012, 10:46:49 am
I'm in for saturday
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 28, 2012, 11:14:01 am
Ja Saturday  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 28, 2012, 11:17:15 am
OK cool. I'll see you at Mogallywood for brekkie at about 9.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 28, 2012, 11:21:10 am
OK cool. I'll see you at Mogallywood for brekkie at about 9.

Where? Physical address perhaps for GPS?
Sorry, don't know the area
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on March 28, 2012, 11:24:31 am
Volroom, Im going to the sasol it's about 15 min fom my spot
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 28, 2012, 11:29:25 am
OK cool. I'll see you at Mogallywood for brekkie at about 9.

Where? Physical address perhaps for GPS?
Sorry, don't know the area



Everyone is meeting at Sasol, but I live about 10mins from Breedt's nek, so I'm not going to ride to joburg and then back again. Best you hook up with WC and I'll see you a bit later. Mgallywood is at the bottom of Breedt's nek on a farm, so no address that a GPS gould figure out. You will need the coordinates.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on March 28, 2012, 11:42:00 am
Cool, will meet up then at Sasol and see you at the farm
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on March 30, 2012, 12:54:31 pm
Yay! Suz managed to get a replacement tail light lens for me! The sticky tape was starting to look a bit kak. I'm going to take in my bike next week to get the steering bearings replaced as well. The bike will then be ready to go! I would like to get one of those LED rear bulbs as well, any idea where to get them from anyone?

*edit* here: http://www.schlowycustomsblog.co.za/?p=1431
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 30, 2012, 04:10:13 pm
I will see you guys there on my XLV 750 R. Hope the ride is gentle enough on my old girl.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 01, 2012, 09:53:25 am
How was it? Didn't make it this time, will do next time. It's actually a good thing..checked underneath my sump for an oil weep when i saw the frame rusted THROUGH on both sides!! Thought this bike was super clean...it was down at the coast and even though elsewhere there seems to be little rust, down there it's another story.

Don't know how to solve this problem. Any ideas? Bike's at Groenie's place at the moment. He thinks it so bad that I need to look for another frame! But there must be some other solution as well..

BTW, having the bike dynoed: good idea. Getting that fuel/air mixture just right yourself it actually impossible, you'll never know. My engine was running way lean. The jerkiness below 3000rpm is gone now, drilled the slide of the carb as well, throttle response much better. didn't touch the spring.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 01, 2012, 03:05:12 pm
Been gone a while ... did fetch that Cruiser from Benoni, and was a good buy . Anyway , while you lads have been busy I've been preparing the wifes bike and ....which DR? .... the new one won the vote ,( better seat mainly, and it's better riding slow )

So I mentioned this idea of using 110mm pipe for storage , check it as applied thus far. I hate panniers, but this pooratech fix adds significant storage in the right place for weight ... won't catch much wind, is dust and rain proof, and very light.

Anyway, had fun with it ....

You can see the bike I created for the Missus's short legs , a dual sport bike with suspension that weighs nothing, and has a seat height of 700mm, and can manage highway speeds ... a tough call eh !

So here's a novel luggage idea for the minimalist : ) .... PS Ceres fruit juice concentrate bottles are the perfect snug fit ...


(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5408.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5412.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5417.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5415.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 01, 2012, 03:11:22 pm
How was it? Didn't make it this time, will do next time. It's actually a good thing..checked underneath my sump for an oil weep when i saw the frame rusted THROUGH on both sides!! Thought this bike was super clean...it was down at the coast and even though elsewhere there seems to be little rust, down there it's another story.

Don't know how to solve this problem. Any ideas? Bike's at Groenie's place at the moment. He thinks it so bad that I need to look for another frame! But there must be some other solution as well..

BTW, having the bike dynoed: good idea. Getting that fuel/air mixture just right yourself it actually impossible, you'll never know. My engine was running way lean. The jerkiness below 3000rpm is gone now, drilled the slide of the carb as well, throttle response much better. didn't touch the spring.

That's WEIRD VR !!!! I reckon someone must have abandoned the bike with a skidplate full of mud to cause that ???? Or it was swum and never drained , or high pressure cleaned and water got it. Scary ! Really am so sorry I never spotted that . I would not hesistate to do some plastic surgery , but I'd not trust my own welds , I'd send it to my mates engineering shop. Bit of a shocker eh?  Am now glad you got a good price on the bike or that would hurt twice as much. So sorry man,  :3some:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on April 01, 2012, 04:32:54 pm
Just weld the frame Volroom, check out the planning a ride section for pics (you missed out on great mud practise, I did a nice gracefull swallow dive over the bars  :biggrin:)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on April 02, 2012, 06:53:45 am
Any suggestions on vibration damping to the grips? I rode with two 640 Adventures for about 300km and they seemed as smooth as butter as opposed to my machine  ???
The vibrations seem worse with my after market bars , about to stand my bike down to a commuter and go dark side for adventure riding.....
The vibes have blown one indicator already.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 02, 2012, 09:18:11 am
That would be the cheapest solution I guess...just frieken weld the frame. I think I'm going with that. I'm really not into the idea of stripping down the hole bike bla bla, no thx.

I also feel the vibration, but getting close to 5000rpm she settles down enough that it's not a problem.

BTW, the indicated speeds were different to what I said before. Rode with the GPS and got (with on tooth less front sprocket)

4700 RPM at 100km/h
5000 RPM at 109-110
5400 RPM at 120

That's fine for me, and Veemax - nice work BTW - the jerksumness is much less after having had it dynoed. Seems that it was running lean and that was mainly why it was not lekka at low speed in town. Much better now.

Didn't gain significant horses, might even have lost one - but that's fine. The bike now pulls very lekka low down and revs all the way through. Slight rich mixture mean going down to the coast will give it more power and not have it running lean. Freeze had to change jets and needle setting around 4 times. Enjoyed the whole experience. You will never know whether your bike is running lean or rich until you have it dynoed it seems. It will remain a guessing game without diagnostics

Will post some pics. WC, will check photo's!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 02, 2012, 11:09:49 am
WC I could not find yer pics on the Ride Planning section , Author ???

VR looks like your gearing is good, and you now have the satisfaction f KNOWING your carb is set up properly ! Great huh !

Back to WC , dude, if a 640 Adv feels smooth you must have a seriaaaas harmonic in those bars ! I never even think of the vibes off my DR .... my bars are not stock , they're Airtime somethings, a little taller than stock , which is great for stand-up. Do the bars you have on now have end weights in 'em ??

If you were here I could offer you about 100kg of lead I've been meaning to take to the scrap dealers ... maybe weight 'em if they aren't ?

I'm busy making my last rocket launching tube today. Let me share a great tip I read someplace ....so obvious .... leave a spray/rattle can in the sun to get hot before using it. You'll find the paint lays much better when it's warm. ( I'm using Rustoleum primer on the PVC , ahead of Velvaglo ....like the Irishman with two condoms ...to be sure to be sure )



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on April 02, 2012, 12:18:27 pm
Quote
BTW, the indicated speeds were different to what I said before. Rode with the GPS and got (with on tooth less front sprocket)

4700 RPM at 100km/h
5000 RPM at 109-110
5400 RPM at 120

That;s pretty much what I get with the 47 rear. I must admit, when I went up Breedt's nek the other day, that lower gearing makes hill climbing a breeze!  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 02, 2012, 01:26:16 pm
Cheap and effective, your idea VM. Only thing for me (why I bought an ATG bag instead of old army style balsak bag) is that when you want to get something out at the bottom, you need to take out everything whereas not the case with panniers and bag with zip
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 02, 2012, 05:51:05 pm
My wife made tube shaped bags that fit snuggly inside those tubes , pretty darned neat, you pull the whole slug and walk off and unzip it.
Of course they are girlie with African prints etc : ) .... gotta love girls on bikes man.

I met this tiny Japanese girl Yuki up way north near the Cunene on a DR250SE all the way from Tokyo via Siberia , Middle East etc, All of Africa. It was her second time around nogal.

The first thing that struck you about her bike was the array of pink clothes pegs on the headlight grill.

Last we saw her she was off to South America.

Interesting choice of bike huh ....DR Suzook !!! Legend.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 02, 2012, 07:52:59 pm
Yeah, you'd think that these extraordinary people are scarce, but we once met a guy in the free state on his bicycle. He came from Spain, but he's American. Alone on a bicycle through Africa...moerse beard. He says he's had a hell of a experience, not every thing good..but still. I take my hat of to them.

LE CAP! I need info: is the pre-96 frame similar to post-96 DR650 frame? Are there slight differences between different countries of production? Like USA, europe and elsewhere (I think my DR is American).

MIght be able to get a post-96 frame from theotherguy, but not sure if the frame is similar (your bashplate for example don't fit pre-96 DR's, because frame mountings different?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on April 03, 2012, 08:30:00 am
DR650 and DR650 second edition have only very very few parts in common. I'd be very surprised to see an early DR engine go into an SE frame without requiring the application of gratuitous violence applied by angle grinders, hacksaws & welding machines.
Remember the SE engine is not just lighter but also considerably smaller in size that the early DR650 mill.

Ditfferences between country models of the same model and year are marginal if present at all.
I rememer some tiny differences in some SE models depending if they were sold with the grab handles or the carrier rack.
Also the atrocious US model SE taillight ::)
Some SE's sold with a rather expensive and söightly undersized and flimsy alii bash plate.
All SE's (SP46) frames are identical apart from the paintjob as far as I know.

I know for sure that the SP41 frame is different from the later SP42...SP45 (head bearings). All SP41 ... SP45 cary the same engines though.

It should be relatively easy (?) to make a bash plate version for the early DR. I have to see if I can use the same shape as for the SE and just do modified mounts but I will need a bike for measuirements since my neighbour at work has sold his SP41.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 03, 2012, 09:13:36 am
You're welcome to take custody of my Velvaglo Ugly Bastid '94 for a few weeks Le Cap , I'm off on a long ride from 11 - 25th April.

Just take note some fukwit stripped the captive nuts underside the frame that hold the bashplate , ( not bothering to retap threads post powder coating ? ) ....so the frame lugs are all backed up with a second nylock nut , which makes things a bit awkward, but I'm not dropping the motor to weld new nuts in place ! : )

You want ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on April 03, 2012, 11:47:17 am
Check dualies to breeds neck in planning a ride Veemax, no bar weights I have alu guards on the bar ends.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 05, 2012, 08:11:15 am
DR650 and DR650 second edition have only very very few parts in common. I'd be very surprised to see an early DR engine go into an SE frame without requiring the application of gratuitous violence applied by angle grinders, hacksaws & welding machines.
Remember the SE engine is not just lighter but also considerably smaller in size that the early DR650 mill.

Ditfferences between country models of the same model and year are marginal if present at all.
I rememer some tiny differences in some SE models depending if they were sold with the grab handles or the carrier rack.
Also the atrocious US model SE taillight ::)
Some SE's sold with a rather expensive and söightly undersized and flimsy alii bash plate.
All SE's (SP46) frames are identical apart from the paintjob as far as I know.

I know for sure that the SP41 frame is different from the later SP42...SP45 (head bearings). All SP41 ... SP45 cary the same engines though.

It should be relatively easy (?) to make a bash plate version for the early DR. I have to see if I can use the same shape as for the SE and just do modified mounts but I will need a bike for measuirements since my neighbour at work has sold his SP41.


Thx Le Cap, so a 93 DR650 has a SP41 frame? If I can get other frame, then frame will be fixed - rusted section cut out, new pipe welded in
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on April 05, 2012, 08:33:22 am
Check your VIN: It either starts off with SP4x... or if it's a slightly later model with 17 digit VIN JS1SP4x...
J = Japan
S1 = Suzuki
SP4x... = type, year model and serial number.

I do not know to what extent SP41 / SP42 / SP43 / SP44 frames are interchangeable. AFAIK only the SP41 has the awkward and expensive head bearing setup with one shoulder bearing on top and a tapered roller bearing at the bottom. From the SP42 onwards they had two tapered roller bearings. (?)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on April 05, 2012, 09:16:20 am
AFAIK only the SP41 has the awkward and expensive head bearing setup with one shoulder bearing on top and a tapered roller bearing at the bottom.
I'm about to find out how expensive as my bike is at Suz to do just that.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Gypsybaron on April 07, 2012, 07:58:52 pm

Thx Le Cap, so a 93 DR650 has a SP41 frame? If I can get other frame, then frame will be fixed - rusted section cut out, new pipe welded in

So, what time did you leave the Mechie's Plekkie?  :biggrin: Did you drop the engine, or fixed the last part of the frame with the engine in place? Dis jammer die oxy-asetileen wou nie werk nie, maar gelukkig kon die arc welder die job doen.

Was lekker om jou en Kykdaar te ontmoet  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 09, 2012, 05:54:05 pm

Thx Le Cap, so a 93 DR650 has a SP41 frame? If I can get other frame, then frame will be fixed - rusted section cut out, new pipe welded in

So, what time did you leave the Mechie's Plekkie?  :biggrin: Did you drop the engine, or fixed the last part of the frame with the engine in place? Dis jammer die oxy-asetileen wou nie werk nie, maar gelukkig kon die arc welder die job doen.

Was lekker om jou en Kykdaar te ontmoet  :thumleft:

selfde man! thx weereens vir daai weld. Die engine het in gebly, eks maar lui. Ons het soortvan reg gekom, stuk flatbar gevat, vas geweld aan eenkant, oor gebuig and weer vas probeer weld. Anit-rust goed aangesit en sy was klaar. Het n aluminium bashplate gekry van Kykdaar, so soortvan generic job. Probeer nou uitfigger hoe om te mount. Dink aan U-bolts.

Sal bietjie foto's wys later.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on April 17, 2012, 03:40:56 pm
So I finally got my new tail light after some wire smacked out the last one. Then I though I'd treat my bike to a LED tail light to unleash a further 0.005KW from the engine. It seem slightly brighter, but the light is better distributed, i.e. not a point source. Here's some pics.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 19, 2012, 09:47:56 am
They work fine on brake light but I heard if installed in flickers because there is a lot less resistance they flicker faster. Also had a LED bulb in the Old XL500R from Schlowy.

I still sorting out the ol girl... last night finished a DIY head light protector. Busy also with bashplate. Got one from Kykdaar; what a nice guy. It's a generic job, so I had to cut away like crazy. Still busy trying to make brackets.

bottom of frame sorted out. Went to Groenie. Gypsybaron was there and helped out. We cut out the bad and replaced. Hopefully this will hold.

Still looking into LED spots; that...will be the last I presume. Since the DR went to the dyno she's running nicely. Airbox abused en ol.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on April 19, 2012, 09:59:24 am
They work fine on brake light but I heard if installed in flickers because there is a lot less resistance they flicker faster.

I had that problem when I installed them on a KLR. You must either put in resistors which kind of defeats the purpose, or get an electronic flasher unit.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 22, 2012, 02:11:40 am
This thread has been quite for a while now. Howzat dogz!?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on April 22, 2012, 09:01:40 am
Howz what? Dawgz
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 22, 2012, 12:58:48 pm
Well, just - maybe an update SuperDave, how far are you on the DR? Wildcoast; what are you busy with currently?
We should go for ride sometime
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on April 22, 2012, 01:28:29 pm
Here's my update.

Waiting for some money to tackle my ambitious project and all of a sudden an Africa Twin with 11 500 km on calls out to me - BUY ME, BUY ME.

Being a nice person who cannot resist pleas for help - I go and buy it.

Now I got too many bikes - for sure as my wife eloquently reminds me.

So my plans for the DR may take a back seat for awhile or I may sell it ( ouch) to help pay for my stunning almost new Africa Twin.

I love the DR - so selling it will be a big decision. I have put much time into it and its only returned the favour with lots of pleasure.

Now I have an added challenge and that is to sell my XLV750r too (maybe) I have spent some time getting her to look good and she performs so well mechanically that it would be sad to see her go. But how many bikes can I ride and maintain realistically?

So I may just end up with 2 bikes - my Honda Blackbird ( maybe) and the Africa Twin definitely.

Some advice here could be useful.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 22, 2012, 09:25:47 pm
too much of a good thing is not such a good thing...I guess. decide which bikes means the most to you, and keep them. I always wanted a blackbird.

I'm spending a lot of time on my DR, and money  -but trying to save money by doing  as much possible myself. Almost there...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on April 24, 2012, 07:55:23 am
Pre 96 thread on drriders.com : http://drriders.com/forum38.html?sid=b259b03d766d9d77a3b62df3284532b9
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 24, 2012, 11:16:40 am
I'm prepping my DR for a trip. Wildcoast came up with the idea of doing a Namibia trip. I'm still keen. So, just a feeler: who is interested in a week long namibia- coming back through Botswana, trip in August sometime? Camping with tents kind of trip. I've  been dreaming about a trip like this for ages
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 26, 2012, 06:23:44 pm
I'm about done..bike looks good. will show some pics but got a nasty surprise just now. I replaced the old chain with DID VX2, I've put on chains before and adjusted, but I see the clip is gone. Master link thank fully still there. So now...can you buy clips apart or do you have to buy the masterlink? What should I get, which chain tool?

I think what happened was that the links weren't compressed enough for the clips to slot in properly even though it seemed like it did. Any experience out there with regards to this issue?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 26, 2012, 08:55:32 pm
Er. Hi ! Been away RIDING , just clocked 12 stunning passes, stitched by 2000km, with the Missus. I took the new DR because it's happy at the lower speeds of my wifes bastard XLX350R. Was a good call , you can't thump the Old DR , you gotta REV it ! I reserve the Pre-96 for hanging with the big dogs , it never ceases being fun to humble a modern bike with an oldtimer .... >:D

SuperDave you and I suffer a similar addiction .... Too Many Bike Itis ? Score on the low km AT man !!! Legend !

I'm at NINE bikes now .... starting to eye the wifes potting shed as potential garage space  :P

Does anyone following this thread think that 220ml oil consumption per 1000km for an 1987 XLX 350 is a warning sign ?

No vehicle in my stable sips oil , or leaks , those two things FREAK me out. Yeah yeah , I like 'em tight !



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 26, 2012, 09:03:55 pm
Here's my update.

Waiting for some money to tackle my ambitious project and all of a sudden an Africa Twin with 11 500 km on calls out to me - BUY ME, BUY ME.

Being a nice person who cannot resist pleas for help - I go and buy it.

Now I got too many bikes - for sure as my wife eloquently reminds me.

So my plans for the DR may take a back seat for awhile or I may sell it ( ouch) to help pay for my stunning almost new Africa Twin.

I love the DR - so selling it will be a big decision. I have put much time into it and its only returned the favour with lots of pleasure.

Now I have an added challenge and that is to sell my XLV750r too (maybe) I have spent some time getting her to look good and she performs so well mechanically that it would be sad to see her go. But how many bikes can I ride and maintain realistically?

So I may just end up with 2 bikes - my Honda Blackbird ( maybe) and the Africa Twin definitely.

Some advice here could be useful.



Oooh I can wax on about this horrible wrenching feeling ! Having to sell one of yer babies ! But you have to start asking yourself honestly what type of riding you actually DO ! I have a Tiger 1050 thats AWESOME but only has 14 000km on it since 07. Ditto my Bandit , 2006 , just clocked 20 000km. The bikes getting the most use are the thumpers !  It's because of my Karoo farm , and the Cape Peninsula , the routes I do the most , in the final analysis. You got to be honest with yourself ... the rides you DO, or the rides you dream about. Take stock of this and there is your answer, even if it pains you.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 27, 2012, 11:14:38 am
I'm prepping my DR for a trip. Wildcoast came up with the idea of doing a Namibia trip. I'm still keen. So, just a feeler: who is interested in a week long namibia- coming back through Botswana, trip in August sometime? Camping with tents kind of trip. I've  been dreaming about a trip like this for ages
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 28, 2012, 05:36:01 pm
does anyone know what ampere hour battery is in the 1993 DR650? Some source says 3Ah..but that's unbelievable. Please tell me it's 7Ah and bigger...3Ah can't handle electric start..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on April 28, 2012, 05:41:06 pm
I thinks mines a 12 , a Quadflex glass-matt , R610.00
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 28, 2012, 07:55:46 pm
Somre pics. I got a bashplate from kykdaar. Was a generic one, not made to fit a DR.. But I made it fit, had to cut some away but in the end it worked out pretty well. Secured it with some brackets I made.even used U-bolts. Pretty tight.

Zeta raisers and hand guards installed, new grips too.

12V socket installed (compressor runs easily off it when idling)

Screen installed

Rust at bottom of frame sorted

Head light perspex cover put on

Found out why the circlip came off. Changed the front sprocket to 15 tooth, the retainer plate was now too big, and touched the bottom part of the links. Could see it when looking at the links. Made plate smaller.

Pretty happy with everything. Just the set of LED spots that I still need to get, and fit the Goose tube with the tools, and I'm done.ready for a lekka trip. No one else keen for a week long trip?  

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on April 28, 2012, 08:22:01 pm
Got a question: oks with Dr's and KLR's are saying that fitting a pumper carp TM40 or FCR "transforms" the bike. Really? Is it that good? Theotherguy has got a TM40 on, does it really make the front end come up under full acceleration in first? I'd rather hear this from people who has done the conversion. There is a TM40 for sale on the forum right now for three grand..I've drilled the slide on my BST40 and throttle response definitely is better. After dyno tune I'm quite happy with power through the rev range but acceleration is not near the required amount to have the front end come up in first without the clutch. Perhaps it better that way, longer life on chain, sprockets and tyres. 
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 01, 2012, 04:05:22 pm
This thread awfully quite..
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 01, 2012, 04:17:36 pm
It might get a bit livelier! After looking at all of those sooper cool Amageza RRs, I have decided to do it next year.

Now for the prep.................


So I need to fit a road book and what else? I have the DR 650 Dakar after all?


Bulletproof mill : check
Upgraded suspension : check
Big tank : check
bash plate :  check
knobblies : check
GPS mount : check
Cool pace on the fairing to stick my number on : check

Apparently for the qualifiers you need a fitted numberplate? Now that will be a challenge. I can't seem to keep one on.  :pot:

???

I think I might extend the screen bit to protect the back of the GPS and road book from mud etc.

Any other tips/opinions?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 01, 2012, 04:56:08 pm
WOW. I don't really have experience to help you here. this sounds like something I might do next year perhaps. In the mean time, when are we going on a trip!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 01, 2012, 04:59:28 pm
Your bike's looking great, where did you get the screen?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 01, 2012, 05:00:38 pm
Hey Veemax, how about the Amageza on old school DRs? That's right in your backyard?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 01, 2012, 06:06:02 pm
Your bike's looking great, where did you get the screen?

It's the extended Dakar (BMW650) screen. Got it second hand for R350 on the forum. Fits like a glove around the front "fairing". Don't know exactly if you fairing looks the same. Gooi a pic there and I'll tell you. Had to drill three holes to secure but it's pretty tight. Does make a difference too when doing highway speeds.

Yeah, I spent quite a bit of money and effort getting her there. now it's just the spots and the tool tube, then I want to go on a trip!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 01, 2012, 06:20:23 pm
OK, I thought it looked familiar. Mine has a fairing and a smallish screen, but it should be quite easy to make one from perspex or polycarbonate that is maybe about 10cm taller.

15t on the front must make a lot of difference. I have a 16t front and a 47 rear. Awesome on the dirt and about 110kph at 5000rpm on the tar, but the dirt handling makes up for the lack of top end. I can wind it to 145, but I don't like to punish the old gal too much.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 01, 2012, 06:55:10 pm
OK, I thought it looked familiar. Mine has a fairing and a smallish screen, but it should be quite easy to make one from perspex or polycarbonate that is maybe about 10cm taller.

15t on the front must make a lot of difference. I have a 16t front and a 47 rear. Awesome on the dirt and about 110kph at 5000rpm on the tar, but the dirt handling makes up for the lack of top end. I can wind it to 145, but I don't like to punish the old gal too much.

we've got about the same gearing now also get around 110 at 5000rpm. It does make a difference - even in town: where before I had to check the tacho the whole time to try and keep her above 3000rpm at low revs, it's not such a big issue anymore! the correct fueling due to the dyno also helps I'm sure. She was running lean before the dynotune. I can accelerate from as low as 2200rpm in 2nd and 3rd depending
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 08:59:52 am
The THREAD IS ALIVE ~!

Hey DB9 , sounds like your bike is Amageza Ready , right off !

Here's a tip , my 110mm PVC pipe luggage system I just finished testing over 1962 km / 12 passes ride on my "new" DR worked so well I'm going to build more like it for the "old" DR , which so far has no luggage system barring a tank bag and soft bag + bungies etc.

My plan was to carry water low low down behind my left knee , to put the COG in the right place , that worked brilliantly , one shorty tube mounted onto the stubs for the left passenger pegs

The horizontal tube, on the other hand, carries :

Syphon pipe
Front and rear spare tubes
Elect fuel pump
Puncture repair kit
Valve tool
Gators
Brush , washing up liquid
Duct tape and cable ties, etc

In other words a self-contained tyre rescue kit, that I can transfer from bike to bike.

(http://i971.photobucket.com/albums/ae199/Veemax/Image1.jpg)

Ja so you want me to do the Amageza ?

When it started I had a lot of mates ask me about this. Actually , in the past 4 of us were all ready to to the Dakar. James my mate negotiated 4 new Honda's from Micor , free. When we added up the costs to build Dakar bikes it came to R360 000 each. Starting with a free bike ! Then entry fee plus plus plus came to around R1.4m each. I wasn't the first to bail mind you , but when the reality hit, when the first dude bailed, it didn't take much for the rest of us to catch a reality check .... we're OLD !!! My mate Pete is fit enough and tough enough to crawl to Dakar on broken glass , the rest of us , it turned out , would rather spend that kinda Tom on something else ! James built a plane and flew it around the world instead , Pete got divorced , Rob stayed at home with a good book, and I retired to the bush!

Hahahahaaa, no man I am too OOOLLLLDDD for that Amageza shit. 50 dude. Yes I could hack it , but don't feel the complusion ! I'd rather 3 or 4 of us went on an awesome ride someplace, as VR suggests. I guess I just don't do crowds any more. Quality company , awesome scenery , and an evening pissup is more my thing.

But when it comes to planning a ride I stand back and wait , as you guys can only ride at set times , with jobs and responsibility etc : ) , I am free , limited only by a Dog.

But if you DO wanna do Amageza , you can count on me to run tech and moral support for you. I am very familiar with the Sutherland environs too. Not many people have the local constable in Middelpos on speed dial hahahahahhahaa. ( Long story with my KTM950 abandoned at the top of Gannaga Pass ! )





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 02, 2012, 11:46:10 am
what an awesome pic! we share the same sentiment. To do a trip however, would mean that we'd have to make it worthwhile for all of us - staying so far away from one another. In other words, it better be a good and proper trip. I was thinking perhaps to  do a trip up Namib and come down through Botswana...in august. But I mean that's just an idea. If there is lekka local routes that we can explore that would be an option too. But the idea for me is like 80 plus percent gravel and even technical, sleep in tents wherever, have lekka braais and beer at night, strong coffee and rusks in the morning and RIDE! i want to see the toughness so proclaimed of the DR myself!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 02, 2012, 12:01:32 pm
http://www.wilddog.za.net/forum/index.php?topic=96914.0

What do you think about this and what is your pref? any experience with the circlip on the master link MIA? or do you rivet your master link with chain tool? If so, what tool? I've got clip on and to keep it there I used epoxy. Maybe next time, I'll use a rivet link with rivet tool...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 12:07:26 pm
I use clip links on nothing bigger than a 200cc farm bike ! I hoesed ( big time ) for a DID chain tool a few years ago. never been sorry , owning this thing is liberating. Bikes and biking is 70% of my life , I never sweat much buying tools because they pay back over and over. You can safety wire a side plate on in place of a circlip , but you hafta have precisely the right guage wire for it to be dependable. No sir. River link or bust.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 02, 2012, 12:20:34 pm
Thanks for the offer of tech support for the Amageza, Veemax!  :thumleft: I would like to do the Amageza, but just to finish, not to race anyone and fark up my bike and possibly myself. I see from the RR's of this years event that finishing the legs in the time specified does not necessarily result in a demolition derby. If an R80GS can finish, then it would be doable on a DR?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 12:35:48 pm
If an R80GS can finish , you could probably have LAPPED it on the old DR  >:D

I think of the old DR as a KTM640 Adv without the marketing , only, more reliable. There is very little difference in their capability and performance. Incremental one-upmanship counts for vokkol in the Tankwa Karoo , when the limiting factor is more likely the biological entity on top !!!

Think of the DR as a KTM with one less horsepower , without bent rims , fork oil leaks, vibration, fuel pump, water cooling parts that can go wrong, and without the  rape of your wallet and dignity if you ever need to buy parts !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 02, 2012, 12:43:28 pm
Quote
If an R80GS can finish , you could probably have LAPPED it on the old DR 

Am I starting to whet your appetite yet?  :mwink:

But seriously, what extra prep would be required apart from fitting a road book? Assuming the bike is mechanically 100%, which I believe mine is, my usual tool kit, spare tubes etc should do the trick? I would maybe get some CO2 bombs for tyre inflation instead of my trusty foot pump?



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 01:11:20 pm
That Tankwa/ Ceres Karoo area below Sutherland , which is UP on the Hantam Plaat and quite different, is a complete utter BITCH for punctures. Random spiky stones can cause stabwound punctures , especially @ speed/aggressive riding. It's a bastard part of the world for that.  Those mushroom gators that 4x4'ers use will potentially save your ass , take 2 ! Definitely go prepared to dismount a tyre. If you hit a dry season the dust will be serious. I'd also squeeze in a spare filter element , or prefilter socks. I usually ride in clean air but in a mass event it's gonna get nasty.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 01:19:33 pm
Here are some pics of the Tankwa Karoo I took last week , awesome eh ? I am sure this pass ( Ouberg ) will be part of Amageza.


(http://i971.photobucket.com/albums/ae199/Veemax/IMG_0329e.jpg)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_0329f.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 01:24:31 pm
More ? This is not a road whose locale I advertise on public domain. Come in person and I'll show yer. If every Dog rode this , the farmers would shut it down for sure .... shhhh ! DR's only need apply !

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_0314c.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 02, 2012, 01:27:05 pm
Cool, I rode through that area last year, great riding. I must make a plan to get down there again.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 02, 2012, 05:54:51 pm
ok...I still have my clip master link on, got an extra one as well. Seems I'll be getting chain tool/riveter. Where did you get your DID chain tool? Can get one at fullstront for about R600. Is it this one you've got?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 02, 2012, 05:55:46 pm
Got a question: oks with Dr's and KLR's are saying that fitting a pumper carp TM40 or FCR "transforms" the bike. Really? Is it that good? Theotherguy has got a TM40 on, does it really make the front end come up under full acceleration in first? I'd rather hear this from people who has done the conversion. There is a TM40 for sale on the forum right now for three grand..I've drilled the slide on my BST40 and throttle response definitely is better. After dyno tune I'm quite happy with power through the rev range but acceleration is not near the required amount to have the front end come up in first without the clutch. Perhaps it better that way, longer life on chain, sprockets and tyres.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 06:04:16 pm
ok...I still have my clip master link on, got an extra one as well. Seems I'll be getting chain tool/riveter. Where did you get your DID chain tool? Can get one at fullstront for about R600. Is it this one you've got?

Snap, thats the one. I paid the same too
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 02, 2012, 06:06:21 pm
Got a question: oks with Dr's and KLR's are saying that fitting a pumper carp TM40 or FCR "transforms" the bike. Really? Is it that good? Theotherguy has got a TM40 on, does it really make the front end come up under full acceleration in first? I'd rather hear this from people who has done the conversion. There is a TM40 for sale on the forum right now for three grand..I've drilled the slide on my BST40 and throttle response definitely is better. After dyno tune I'm quite happy with power through the rev range but acceleration is not near the required amount to have the front end come up in first without the clutch. Perhaps it better that way, longer life on chain, sprockets and tyres.

My DR will loft with the stock carb , but watch out, huuuuggggeeeee altitude factor eh ! There be actual Oxygen down here !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 03, 2012, 06:52:46 pm
ok...I still have my clip master link on, got an extra one as well. Seems I'll be getting chain tool/riveter. Where did you get your DID chain tool? Can get one at fullstront for about R600. Is it this one you've got?

Snap, thats the one. I paid the same too

When did you buy yours? A decade or two ago? Le Cap says the "workshop" version which I think is the same, is costing R1350...
Too much.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 03, 2012, 06:54:54 pm
Got a question: oks with Dr's and KLR's are saying that fitting a pumper carp TM40 or FCR "transforms" the bike. Really? Is it that good? Theotherguy has got a TM40 on, does it really make the front end come up under full acceleration in first? I'd rather hear this from people who has done the conversion. There is a TM40 for sale on the forum right now for three grand..I've drilled the slide on my BST40 and throttle response definitely is better. After dyno tune I'm quite happy with power through the rev range but acceleration is not near the required amount to have the front end come up in first without the clutch. Perhaps it better that way, longer life on chain, sprockets and tyres.

My DR will loft with the stock carb , but watch out, huuuuggggeeeee altitude factor eh ! There be actual Oxygen down here !

Yeah...I hear you. I've sorted out my BST-40, so not interested in TM40. Drilled the slide as well, definitely more peppy. My carb is set so very slightly rich, so if I do come done there hopefully she'll be aloft as well in first!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 03, 2012, 06:55:49 pm
So what about the idea of a proper DR trip some time this year... is it doable? I can in august
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 04, 2012, 03:52:41 pm
So what about the idea of a proper DR trip some time this year... is it doable? I can in august

Just wait a month and then come to the bash in Sept. I'm definitely going.............
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 04, 2012, 05:48:44 pm
So what about the idea of a proper DR trip some time this year... is it doable? I can in august

Just wait a month and then come to the bash in Sept. I'm definitely going.............

I've got free time in August, what bash, when and where exactly?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 04, 2012, 08:17:11 pm
http://www.wilddog.za.net/forum/index.php?topic=96764.0;topicseen
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 05, 2012, 05:02:40 pm
Tempting ... moerse ride from Cape Town .... and I did it a trip like that Leostho direction , and all of Lesotho for that matter .... last year .....

It's probably gonna get over subscribed isn't it ?

I'll watch the thread but by Sept ???

If you go I'll go !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 05, 2012, 05:24:57 pm
So you're going then?  :laughing4:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 15, 2012, 09:30:33 pm
I've looked but I can't find a solid source for battery output for 1993 DR650. Manual says it's 5Ah, I would have thought that the battery in it is bigger than a 5Ah one. Reason for asking, I've got a trickle charger and it says minimum 7Ah.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on May 16, 2012, 10:07:22 am
Don't use a trickle charger on a starter battery.
Trickle chargers are made for storage / deep cycle batteries as used in camper vans, boats, UPS, alarm systems etc.
Trickle charging a starter battery will cause sulfation and premature failure.

Best to get an AGM battery which will not require any maintenance charging for months due to its extremely low self discharge rate.

If you want / have to use a flooded cell battery (which is a kark idea in a dirt bike which gets dropped occasionally) use an ordinary maintenance / workshop charger and charge the battery once every month until the charging current drops to near zero. If you're lazy get an automatic "intelligent" maintenance charger which cyclically recharges the battery.

Don't get an intelligent charger for an AGM since you are wasting your money.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on May 16, 2012, 10:14:42 am
The battery should be an MF YTX4L-BS which has a capacity of 3Ah (?)

The charging systems power output should be (rated at) around 10A equivalent to 120W (guess).
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 16, 2012, 05:59:58 pm
Don't use a trickle charger on a starter battery.
Trickle chargers are made for storage / deep cycle batteries as used in camper vans, boats, UPS, alarm systems etc.
Trickle charging a starter battery will cause sulfation and premature failure.

Best to get an AGM battery which will not require any maintenance charging for months due to its extremely low self discharge rate.

If you want / have to use a flooded cell battery (which is a kark idea in a dirt bike which gets dropped occasionally) use an ordinary maintenance / workshop charger and charge the battery once every month until the charging current drops to near zero. If you're lazy get an automatic "intelligent" maintenance charger which cyclically recharges the battery.

Don't get an intelligent charger for an AGM since you are wasting your money.

The trickle charger i've got specifies that it's for motorbikes batteries, 0.2 amp charging (don't know if that's per hour or minute). It charges till 13.5V potential difference is measured across battery terminals, then it discharges it to 13V, and starts again to charge to 13.5V etc. How is this bad for the battery? How would this cause sulfonation?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on May 16, 2012, 07:08:45 pm
Well I have returned to EL now folks. The trip blew my motor , so she is pieces at present...... >:(
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 16, 2012, 08:54:48 pm
Good to hear of you again WC, been rather quite around here the last while. Sorry to hear about the motor! What happened? ceased? how did you get to EL then?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 16, 2012, 08:57:39 pm
The battery should be an MF YTX4L-BS which has a capacity of 3Ah (?)

The charging systems power output should be (rated at) around 10A equivalent to 120W (guess).

When you refer to AGM battey Le Cap, I take it you are talking about Yuasa batteries? I saw on the website that the discharge rate for the calcium batteries was much less than "normal" ones. How much more expenxsive are they?

Say for a 1993 DR650 and a R1150GS?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 16, 2012, 10:52:56 pm
Well I have returned to EL now folks. The trip blew my motor , so she is pieces at present...... >:(

Aw maaaaan , tough break ! Hope it's not too serious ?  Not often a DR FAILS !   After all the work you've put in , just ain't fair.

But better a enjin shot to hell than an injury upon your person !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on May 17, 2012, 05:45:50 am
Well I have returned to EL now folks. The trip blew my motor , so she is pieces at present...... >:(

been there,  done that.
only thing salvageable with mine was the head,
yes,  EVERYTHING below the head was destroyed.
i know your pain,  and hope for the best.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 17, 2012, 09:03:05 am
 :o what happend WC?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on May 17, 2012, 09:28:38 am
Well I have returned to EL now folks. The trip blew my motor , so she is pieces at present...... >:(

Oh no!

Call me regarding the rebuild - i may have something to share with you. oh 8 three 3 nyn fyf 9 one fyf zero
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on May 17, 2012, 10:12:42 am
The battery should be an MF YTX4L-BS which has a capacity of 3Ah (?)

The charging systems power output should be (rated at) around 10A equivalent to 120W (guess).

When you refer to AGM battey Le Cap, I take it you are talking about Yuasa batteries? I saw on the website that the discharge rate for the calcium batteries was much less than "normal" ones. How much more expenxsive are they?

Say for a 1993 DR650 and a R1150GS?

AGM = Absorbent Glass Mat sometimes also referred to as VRLA (Valve Regulated Lead Acid) battery, NOT identical with Lead Calcium which is only a sub type of flooded cell lead acid.
THe AGM / VRLA is recognisable from having no (easily) removable filler caps.
You can operate it on its side and even uposide down since the electrolyte does not slosh around but is absorbed and held in place by a glass fibre mat hence the name.

A MotoBatt MBTX4U retqails at around R 300. The equivalent Yuasa YTX4L-BS might be a few bucks more.

Not 100% sure which size battery the R1150GS takes. Will find out.
Edit: Can get both MotoBatt as well as Dynavolt for R800
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on May 17, 2012, 10:26:47 am
Don't use a trickle charger on a starter battery.
Trickle chargers are made for storage / deep cycle batteries as used in camper vans, boats, UPS, alarm systems etc.
Trickle charging a starter battery will cause sulfation and premature failure.

Best to get an AGM battery which will not require any maintenance charging for months due to its extremely low self discharge rate.

If you want / have to use a flooded cell battery (which is a kark idea in a dirt bike which gets dropped occasionally) use an ordinary maintenance / workshop charger and charge the battery once every month until the charging current drops to near zero. If you're lazy get an automatic "intelligent" maintenance charger which cyclically recharges the battery.

Don't get an intelligent charger for an AGM since you are wasting your money.

The trickle charger i've got specifies that it's for motorbikes batteries, 0.2 amp charging (don't know if that's per hour or minute). It charges till 13.5V potential difference is measured across battery terminals, then it discharges it to 13V, and starts again to charge to 13.5V etc. How is this bad for the battery? How would this cause sulfonation?

It does not cause sulfation like continuous trickle charge does in starter batteries.
But it causes the plates to distort like normal operation of the battery would.

Using an "intelligent" maintenance charger on a flooded cell battery is just like cycling the battery on a daily basis. The charger is therefore best referred to as a charging cycle charger. There isn't anything intelligent about them.
From a wear point of view it's like cranking your engine for a minute or so and then starting the engine & recharging the battery.

The AGM basically goes dormant and thanks to its very low self discharge you don't need to do anything to it even if it stands for a month or three.
This makes an AGM starter battery way superior in all applications where the battery is used intermittendly. Bikes, jet ski etc.
No leakage if tipped over or inverted, a generally longer service life if compared to flodded cell and the fact that they pack more punch for a given capacity (both "cranking power" and useable capacity) are other advantages.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 17, 2012, 10:27:02 am
MotoBatt, the YELLOW ones ? I've been buying those from Craigs for DR , and Cruisers ... are they any good ?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 17, 2012, 10:27:52 am
Asked and answered , crossed postings ! : )
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on May 17, 2012, 10:31:51 am
MotoBatt, Dynavolt, Yuasa AGM's are good. Koyo is still good but I'd rather buy a Yuasa and pay R200 more.

Not so good according to my experience: Himura. Two died within less than three months, the second one being the replacement for the first ::)
Yacht. Two dead ones, both looked suspiciously new & clean ???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 17, 2012, 10:35:07 am
Had a Yacht let me down .... that's confirmation then !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 18, 2012, 03:26:56 pm
With regards to WC's breakdown...he recently fitted a free flow silencer. I have heard the following before: so called "back pressure" is needed to keep the flames inside of the cylinder/head - combustion chaimber - whatever as the exhaust valve opens for the exhaust stroke. There is a measure of overlap, so the exhaust valve can start to open even before the piston comes up for exhaust stroke (??)

Point is that i've heard that you can burn valves when there is no back pressure. You will definitely burn valves in a petrol engine when there is no header pipe from the exhaust ports - why? because there is no back pressure. Back pressure is due to obstruction within the exhaust system. So a silencer with baffles and what not affords that back pressure (no burning of valves then), and also decreases the noise.

Did you burn a valve then, WC?

I recently fitted a 2nd hand akro on my R1150GS, before - exhaust gas flow out of canister was very little, surprising for the size of engine - having changed to the free flow option, much more gas flow. The stock silencer definitely provided SOME back pressure.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 22, 2012, 11:28:59 am
No Veemax, this thread is not alive...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 22, 2012, 11:41:34 am
Ja ja I marked your trip story unread as I know I should get back to you , but am busy organising my 50th birthday bash this Saturday !!! >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 22, 2012, 12:30:00 pm
I currently have a BIG problem on my DR! And the parts to fix it are NOT AVAILABLE. What to do!  ???
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 22, 2012, 12:38:27 pm
I have back door contacts in USA and Germany , wanna try gimmee a list of critical stuff ?

Try buy a whole motor from a BIG market , look at Craigslist ?

Sorry for yer woes bru.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 22, 2012, 12:49:25 pm
 >:D Ja, the problem is I have completely worn out my back tyre and they don't make D606's any more!!!!  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 22, 2012, 01:01:27 pm
[size=40t]

HOOK LINE AND SINKER  :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer: :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 22, 2012, 01:03:24 pm
 :laughing4:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 22, 2012, 01:04:00 pm
My Old + New DR's are running KT966's on Le Caps advice.

Sometimes ze Germans know stuff : )

So far doing a great job , just done 2000 km trip so getting to GRIPS with it ...gettit gettit ?????????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 22, 2012, 01:10:28 pm
I was thinking of trying Mitas CO2, but I haven't got round to it yet. Currently I'm just riding the DR like a speedway bike....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 22, 2012, 02:18:45 pm
Lekka...It's expensive, but it seems it's a TOUGH tyre: Mitas E09, actually a tubeless with strong side walls and rubber compound is stronger than normal or something.

Enjoy u'r 50th VM!! when is it?

I'm still keen for a trip some time, a proper one
Who's keen? Maybe Botswana, cross over to Namib and back or something.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 23, 2012, 08:35:37 am
Go look on trade/smalls - there are some tyres for sale there at good prices. A Mitas E09 130/90/17 going for R880. They go For R1100 in some places.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 24, 2012, 10:49:29 am
WC, what's happening bud? Post some pics of the engine - what exactly happened to it?

BTW, must say that I'm happy with how my DR is now pulling. Freeze did a good job with dyno. You won't believe but I've got rather small main jet on the carb, think it's 144 (dyno kit sizes). We started with 155, the kit had main jets up to 170! With the tapered needle, it seems there is alot of petrol coming through just in changing the needle. Consider that as you try and get the fuel/air right with yours.

Had to free flow the silencer to get the probe in their for the dyno. that was interesting...used a welding rod to burn holes in the plate. Had to weld two welding rods together to get in deep enough! DR very loud now, but I ride with ear plugs

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 24, 2012, 11:12:13 am
Going to try a Pirelli rally cross rear. Has a similar tread to a D606, seems a bit lighter though? I'll fit at the weekend.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: theotherguy on May 24, 2012, 11:20:15 am
Going to try a Pirelli rally cross rear. Has a similar tread to a D606, seems a bit lighter though? I'll fit at the weekend.

R?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 24, 2012, 11:47:50 am
Going to try a Pirelli rally cross rear. Has a similar tread to a D606, seems a bit lighter though? I'll fit at the weekend.

R?

R?

Dunno.

This one:

http://www.pirelli.com/tyre/ww/en/motorcycle/sheet/mt_21_rallycross.html

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 28, 2012, 12:14:13 pm
DP9..missed you on Sunday...what  a ride!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 28, 2012, 12:20:29 pm
What happened on Sunday?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 28, 2012, 01:25:59 pm
What happened on Sunday?

http://www.wilddog.za.net/forum/index.php?topic=98697.0
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Manfred on May 31, 2012, 12:29:10 pm
Guys, was doing a cleanup on my laptop, all things DR.
Came across a service manual for the DR650 R/S

Ive attached the first page and the size of the zipped files.
Just in case someone was looking for them.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Manfred on May 31, 2012, 12:32:32 pm
Ok, only one zipped file. Looks like they are all the same.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on May 31, 2012, 03:46:07 pm
Ok, only one zipped file. Looks like they are all the same.
So you don't have the service manual?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Manfred on May 31, 2012, 04:38:12 pm
Lol. I do. Its about 10 Mb for all three. just in case they arent the same
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on June 01, 2012, 05:35:31 pm
Maybe I'll see you some time and I can then download service manual on a flash

Question: who in JHB area with DR want to build their own crashbars for the ol DR?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on June 01, 2012, 06:13:46 pm
Maybe I'll see you some time and I can then download service manual on a flash

Question: who in JHB area with DR want to build their own crashbars for the ol DR?

Does it need them? There's nothing sticking out apart from the oil cooler?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on June 01, 2012, 06:29:45 pm
Maybe I'll see you some time and I can then download service manual on a flash

Question: who in JHB area with DR want to build their own crashbars for the ol DR?

Does it need them? There's nothing sticking out apart from the oil cooler?

On www i've seen pictures of cracked magneto covers and worse. If you fall and a protruding rock is in the wrong place a lot of the engine is exposed really. Also, would be nice if you could protect the tank some.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on June 01, 2012, 07:07:11 pm
count me in on the crash bars.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on June 01, 2012, 07:25:02 pm
Just got this question VM, your avatar message says real adventure bikes weigh less than 150kg. That leaves out the DR to my understanding, not so? The old DR is that we've got weighs in at around 170kg DRY! Fully fueled, your talking close to 200kg - or am I mistaken?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on July 11, 2012, 08:14:38 am
Hello strangers ! Yes you are right Volroom my ole DR does weigh quite a bit more than my ( PLAB ! ) new DR , but even with a Stage 2.0 mod my new DR will get whipped by my own bone stock 94 Velvaglo special ... it more than makes up for it's lardass with ole fashioned bhp.

Speaking of which , I have been battling with 2 irritating oil leaks. One from the exhaust tappet cover easily overcome with flat filing some distortion out of the cap. But the oil return pipe has had me had a go at it THREE times.

The solution ? A few winds of thread tape on the pipe end in the groove where the O-ring seats , increases its diameter very slightly , forcing a bit more squish on the O-ring under assembly. AT LAST. So simple.

Anyway , yesterday to test my oil tight engine I whipped it's ass under flat out riding on the very bumpy road around Cape Point , where, under miserable Cape weather , one can own the road in winter.

Well , another weakness ...well....only just a weakness.....showed up. Under wide-open , balls to wall horsepower , and extreme bumps , the cltch springs gave way from time to time , allowing the clutch to momentarily breal friction. Damn.

So now on my To Do list are heavier springs.

This is not the first Suzuki I've owned that shows up marginal springs , there have been others.

My VZ800 is known for this too.

For that bike there is a forum prompt to Vezrah springs , any one know of a common aftermarket clutch spring fix for the pre-96 DR's ??

Other than that , my ole DR is proving to be an absolutely BRILLIANT bike. Reliable , tough, gives a darn good account of itself in much more expensive company , and I get frequent offers to sell it to mates , especially GS12 owners who are continually surprised when this Khaki weapon leaves 'em for the Road Bike they are , in the dirt. Hell yeah !!!

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on July 15, 2012, 03:13:09 pm
Good to see you back VM, don't know about the clutch springs. Sorry. I fitted LED spots to the DR yesterday, I did one of the stupidest things ever...after checking the oil level - taking it off its stand first, I forgot the stand was not out and...allowed it to fall flat! Wow... need to know, anyone got a pair of old flickers lying around they are willing to sell?

Gonna look at making some crashbars soon. Will post pics. Here are some of the LED spots and brackets I made.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on July 15, 2012, 04:01:24 pm
Neat job there , and I like the spots because they are hardly intrusive ! Very compact. Niiiiiice. How much difference do they make on a dark road at night ?

I have 3 stock DR flickers , but I better keep 'em , already had to use one thanks to fukwit cage driver who reversed over my bike.

Yes the camo is working ?

HAhahahahaha

Actually the bike was parked next to a bright red GS so no excuse.

I know this is completely off topic , but eyeball the bike I've been Vroeteling since my 94 DR project. This is recycling day at Veemax workshop hahahahhaa

(http://i971.photobucket.com/albums/ae199/Veemax/TheHorror9June2012.jpg)



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on July 16, 2012, 09:55:59 am
Interesting plaything there..

The LED spots makes a moerse diff. Check out 4X4direct.co.za, they are R410 a piece on special now. They are worth it..., telling you
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on July 29, 2012, 10:33:53 am
Veemax, what does the stock handlebar of the old DR's look like? I've got an aluminium one with a cross brace. Want to know if it's stock. Can get a pro taper handle bar, but if the item i've got is aftermarket I might refrain from buying.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on July 29, 2012, 09:47:58 pm
Hey , thats odd , I am also currently contemplating bars ! Firstly , my bike has taller Airtime bars , I bought it like that. GREAT for standup , and short squirts , maybe a bit too tall for open road. So er...I dunno what stock OEM bars look like either ! Alpha-Sports microfiche shows the factory bars are quite flat , which makes sense for predominantly road use. I have a plan to switch my wifes XLX350R bars , which are wide/flat with less pullback, to my DR , and put on her bike some KLR650 bars I have in stock , which are narrower with more pullback , better suited to a smaller kortgat vrou : )

I was gonna try that for a while , to see if I prefered low/flat/wide. The Airtime bars are real 'begging dog' bars around town , but man , when yer butt starts to ache , and you stand UP on the pegs , you are Lord and Master of the stand-up world , and you sit IN the bike when planted.

Hard to say which is the best arrangement ! But higher bars , and a 12mm spanner in yer pocket , seems the smarter choice, you can adjust the bars a little away from your chest for long trips at higher windspeed. Flat / Low bars might be cool round town , but probably less versatile in the long run. ( Which is why so many adventure riders seem to buy spacer kits ??? )

The trick, I guess, is to not shy away from trying a different setup , even though it's WORK to change 'em !???

I am not too fussed about what metal they are , a few 100gr ain't gonna swing my decision, and any oke whose done long distance on a KTM640 pile-driver , is immune to the vibes variable ! : )

I still think a 94 DR is smooth as silk ! Hahahahahhaaaa.




Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on July 30, 2012, 09:20:32 pm
Maybe I'll see you some time and I can then download service manual on a flash

Question: who in JHB area with DR want to build their own crashbars for the ol DR?
Me!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on July 31, 2012, 08:54:04 am
Maybe I'll see you some time and I can then download service manual on a flash

Question: who in JHB area with DR want to build their own crashbars for the ol DR?
Me!

Well ok Dave, how about this weekend?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on July 31, 2012, 09:24:44 am
Hey Volroom , the handlebars pic you requested , which I believe to be "Airtime" bars , as they originally had a crossbrace foam covering of that name , which I think I binned, for it's gawdy red-on-gloss-black look , which is obviously not in keeping with my "colour" scheme  >:D

(http://i971.photobucket.com/albums/ae199/Veemax/DRBars.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DJ on July 31, 2012, 09:37:14 am
Good to see you back VM, don't know about the clutch springs. Sorry. I fitted LED spots to the DR yesterday, I did one of the stupidest things ever...after checking the oil level - taking it off its stand first, I forgot the stand was not out and...allowed it to fall flat! Wow... need to know, anyone got a pair of old flickers lying around they are willing to sell?


Hey volroom, I got some indicators for my DR350  from Suzuki Toy Store in Centurion for R60 each for the short stemmed ones and R90 for the longer stemmed ones.

Or you could try Startline in Edenvale, they have an assortment of indicators.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on July 31, 2012, 09:52:10 am
Maybe I'll see you some time and I can then download service manual on a flash

Question: who in JHB area with DR want to build their own crashbars for the ol DR?
Me!

Well ok Dave, how about this weekend?
Sounds good - but will be able to confirm by Friday.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Gypsybaron on July 31, 2012, 01:46:11 pm
Runner has those nifty indicators with flexible stalks as well, R150 for 2.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Gypsybaron on July 31, 2012, 01:47:02 pm
Remember to ask for WD discount, though! :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on August 01, 2012, 03:24:48 pm
Good to see you back VM, don't know about the clutch springs. Sorry. I fitted LED spots to the DR yesterday, I did one of the stupidest things ever...after checking the oil level - taking it off its stand first, I forgot the stand was not out and...allowed it to fall flat! Wow... need to know, anyone got a pair of old flickers lying around they are willing to sell?


Hey volroom, I got some indicators for my DR350  from Suzuki Toy Store in Centurion for R60 each for the short stemmed ones and R90 for the longer stemmed ones.

Or you could try Startline in Edenvale, they have an assortment of indicators.

Gr8 Dale , I need to go have a look. That's quite cheap. I saw another dog the other day with big boy flickers that didn't even have stems, just a bracket. Cannot break if fall. Was thinking of that. Need to get some time to go check things out.

Well, VM - let me know if you don't need the handlebar anymore.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on August 01, 2012, 03:25:26 pm
Hey Volroom , the handlebars pic you requested , which I believe to be "Airtime" bars , as they originally had a crossbrace foam covering of that name , which I think I binned, for it's gawdy red-on-gloss-black look , which is obviously not in keeping with my "colour" scheme  >:D

(http://i971.photobucket.com/albums/ae199/Veemax/DRBars.jpg)

VM, where did you get those mirrors! I need proper ones.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 01, 2012, 03:30:41 pm
They jumped ship from my 2009 DR : ) 
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 01, 2012, 03:34:09 pm
http://www.wemoto.com/bikes/suzuki/dr_650_se_sp46a/96-03/picture/mirrors_pattern_pair/

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on August 06, 2012, 06:00:00 pm
Thx VM, will check it out

So, VM, are the progressive springs worth it? I can get some springs up here in JHB. I don't know if it's time for my springs to be changed, but if I go on a trip the front end needs to be sorted. Did you have your rear shock rebuilt as well?

Imagine, you can fit ohlins to the DR...think you get a rear shock for it
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 06, 2012, 07:29:32 pm
Thx VM, will check it out

So, VM, are the progressive springs worth it? I can get some springs up here in JHB. I don't know if it's time for my springs to be changed, but if I go on a trip the front end needs to be sorted. Did you have your rear shock rebuilt as well?

Imagine, you can fit ohlins to the DR...think you get a rear shock for it

You can have the shock rebuilt and modified for a fraction of what the Ohlin would cost if you could get an Ohlin for it. Shimwells do a repair and mod and I think it works out around R2000. Almost the price of the DR (LOL) :imaposer: :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 15, 2012, 10:27:43 pm
Thx VM, will check it out

So, VM, are the progressive springs worth it? I can get some springs up here in JHB. I don't know if it's time for my springs to be changed, but if I go on a trip the front end needs to be sorted. Did you have your rear shock rebuilt as well?

Imagine, you can fit ohlins to the DR...think you get a rear shock for it

Hi, sorry, been in the bush for two weeks again ! I ordered Progressive's springs for the front as the cheapest solution to ole saggy stockers , turned out a good buy because it comes with plastic spacers you can saw bits off until you get the spring rate that feels right. I think the back shock is bone stock. I've worked it real hard on a few rides Ooop North in the Tankwa and find it hard to fault. The ole DR is not quite a replacement for my KTM640Adv I had , but it sure comes close , which is really saying you pay a huge huge price for the incrementalism offered by 'ready to race' marketing.  I am SO OVER marketing. Thus Velvaglo counterculture !!!

Put this way , now at age 50 , I don't give a sideways sh^t not being the fastest Rambo on the block. And in the combination of bike + rider , the bike is not the limiting factor , even my ole DR.

Given that I have time and ride mostly in the week when I own all the backroads .....heh heh heh.... there is no-one to prove anything to anyway !

BTW , a little less headspace in the fork air gap can restore some ride height , but you gotta be careful with this kinda tweak , hydraulic lock is NOT your friend !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on August 16, 2012, 11:10:15 am
I put progressive front springs in my DR, made a huge difference. Much more planted on the road. Also the fork oil was probably the same oil the factory put in so that would have helped as well.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: volroom on August 20, 2012, 11:06:55 am
Thx, think I'll soon get myself some wilbers progressive springs from Doc KLR. My front end is not very soft, think the OEM springs still doing an Ok job. I heard of a front fork brace that increases stability on the front end. Can get one for around R1300. It connects to the front fork stanchion...don't know if that's right. Sort of where the bottom part of the fork boot is held by a tie strap/cable tie.

http://www.rswracing.com/dr650.htm

Supposedly this can help..upside down forks are said to be beter...I mean KTM only go for those..something about it having compression damping and ........there are two types of damping, whereas the other kind of forks (like the DR) only has one kind of damping...Front shocks that is. I am talking under correction here.

Like VM says, normally the bike is rarely the limiting factor, but suspension does play a big role in how stable the bike feels off road i think.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 20, 2012, 02:34:00 pm
And hey , an oke gets bored and has to vroetel !!!!!

I've just been photographing my VZ800 project bike which is FINISHED , so now I dunno what next ...

I'm just checking my mails here then descending into my dungeon , probably gonna violate the wifes 650 Savage , in my head there is a flat tracker waiting to be born !

My oldtimer DR needs an oversize O-ring on the oil return , what a mission, and maybe a one-up pilot air jet , but dammit , can't find anything to do on it now : )

Phhewwwww these bikes go well ! Mine gets blasted full bore on the highway here at sea level , and I run out of road before running out of power. Just love it man. Don't miss my KTM for a single second.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 20, 2012, 03:17:06 pm
SO my rebuild mission hasn't gone to plan.

Wife is really having a go at me because there too, far too many bikes. So I am told no hairy expensive mods.

This means I need a set of rings for my DR650 - 1993 - think it is SP45? Bore need to be honed and rings fitted, Head getting a reseat of valves and new stem seals.

But - I need to confirm if std size or over size needed.

Wife insists I sell her. ( that would be the bike unfortunately).

We'll see when she re assembled.

Does anyone know about a vent filter? That wears out over time and should be replaced with a cotton washable ( K+N Type) filter? Bit lost here  - saw the pic on Procycle but ...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 21, 2012, 01:04:53 pm
Vent filter ? Don't you have positive crankcase ventilation to the airbox ? ( I don't really know for sure what I am talking about , but pretty sure my old DR has a pipe to the airbox from the cases )

Your wife sounds wise and sane , if it wasn't for our Handbrakes, we'd be living in a garage on a dusty old single bed , with a fridge full of beer, and be living on junk food ...

But then , my strategy is better , inflict them. My wife has THREE bikes , and I have just the basic 6 .....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 21, 2012, 01:57:03 pm
Seems the post 1996 has a secondary breather filter located by the tank - this must be what was being referred to by Procycle.

My wife has a bike but also has mood swings - so some days its cool to have all these bikes and then other days I get a real k@rk attitude accompanied by a pk to the side of my head.

Eish - the things we have to endure for our woman. LOL

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on August 21, 2012, 03:58:50 pm
Superdave my brothers bike(Suzuki DR650) still need a Engine so please let me know if you want to sell yours seems they are made of unobtainimum...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 21, 2012, 05:24:33 pm
Zetman - I am in process of honing cylinder and new rings as well as doing valve seats, stems and guides.

Depending on cost of this - I may well consider selling. but she is generally a good example of DR650. Lets wait and see - will know by thursday what route I am going to follow. We can talk then.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 21, 2012, 05:57:59 pm
I was considering selling mine , but when I realised that I'm in R42 000 , whooooaaahhh , no-one will give me that for it , but , fork it , it's NEW !!!

So now I guess it's a lifer.

When the cylinder/bore clearance is NEW, the Valves, guides, seals etc NEW , ALL the carb wear parts including unobtainable plastic slide and guide NEW , the disk rotor NEW , the clutch and cam chain NEW , the tyres NEW , the swingarm bearings NEW etc etc etc , then you shitty it up painting it khaki , you are sitting with an overcapitalised self-indulgent bike. HAHAHAHAHAA.

Oh well , better two DR's, that get used, than a Harley parked at Viper Lounge , I reckon.  >:D

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on August 21, 2012, 09:13:37 pm
Weet eenige iemand dalk van n engine iewers te koop al is dit net die ratkas gedeelte my boet se bikeratkas het ontplof kan ni regmaak nie kan iemand dalk help asb?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 21, 2012, 10:03:47 pm
I was considering selling mine , but when I realised that I'm in R42 000 , whooooaaahhh , no-one will give me that for it , but , fork it , it's NEW !!!

So now I guess it's a lifer.

When the cylinder/bore clearance is NEW, the Valves, guides, seals etc NEW , ALL the carb wear parts including unobtainable plastic slide and guide NEW , the disk rotor NEW , the clutch and cam chain NEW , the tyres NEW , the swingarm bearings NEW etc etc etc , then you shitty it up painting it khaki , you are sitting with an overcapitalised self-indulgent bike. HAHAHAHAHAA.

Oh well , better two DR's, that get used, than a Harley parked at Viper Lounge , I reckon.  >:D

Now thats my challenge!


Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 23, 2012, 09:45:24 am
Happy to report that my DR engine still in excellent condition.

The compression rings seemed to have failed - possible overheat situation - so I will check out oil cooler and maybe go for larger cores to aid cooling.

The cylinder bore is very good and needs a little honing,and piston is spot on. but it is 95.5 and not 95 and herein  lies my challenge. New oversize rings. Where to get locally and quickly?

Valves and guides are all good - but the motor engineer feels the exhaust valve stems are a little thin and would be happier fitting valves that have slightly larger stem diameters. I asked if we could increase size of the port by 2 mm as well. Don't know if it would help with anything coz inlets will remain the same. Waiting on his feedback.

Any info in this regard would be appreciated. I have my own ideas - but am open to advice from those in the know.

So i am back at the point where - do i ceramic coat piston and combustion chamber as well as the outer of the cylinder head or do I just put together and run in and sell it?

Please don't let my wife read this thread or I am going to be in hospital for a while after she klaps me good and solid with a lead pipe. :imaposer: :imaposer: :imaposer: :imaposer: :imaposer:




Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on August 23, 2012, 12:50:27 pm
Hmmm please help me find a engine for my Boets bike we need to  :ricky:

Superdave i wont tell your wife if you help us... :pot:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 23, 2012, 01:19:52 pm
Zetman - now you resorting to veiled threats!

jis - I cant even share my deepest most personal thoughts here.

 :imaposer: :imaposer: :imaposer: :imaposer:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 23, 2012, 08:53:05 pm
valves are actually ok. Guides are good. So new stem seals and reseating valves.

Bore is excelent - now honed.

Piston is great - need 0.5 oversize rings.

Ceramic coating of piston and combustion chamber and valves as well as external barrel is now calling out loudly to me.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 24, 2012, 08:09:30 am
What's the piston/bore clearance measure SD?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on August 24, 2012, 09:57:40 am
Standard finished cleaarance of a +/- 100mm sleeved bore to piston would be between 0.045mm and 0.070mm.
Wear limit is often given as 0.10mm and something like 0.02mm out of round.

Perfornace piston manufacturers sometimes call for slightly larger clearance than standard factory spec. Not all wonderful. Reason is the lighter forged piston heats up and expands quicker on start up leading to seizure if it's not cleared enough. The larger piston to bore clearance unfortunately also leads to higher wear of piston & rings :-\
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 25, 2012, 08:20:40 pm
What's the piston/bore clearance measure SD?

Not sure of exact measurements / clearance. But all good - I have sourced a set of rings and need to check it out with motor engineer.

So if it meets specs as per Suzuki we going to do the piston coating, combustion chamber and probably inside bore of exhaust header.

Also doing slide mod on BST40 carb. I have a GSXR 1000 can that I can fit as well. So looks like its coming together.

Will be making a Pooratech tool tube then should look at making crash bars.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 29, 2012, 05:36:38 pm
What's the piston/bore clearance measure SD?

Not sure of exact measurements / clearance. But all good - I have sourced a set of rings and need to check it out with motor engineer.

So if it meets specs as per Suzuki we going to do the piston coating, combustion chamber and probably inside bore of exhaust header.

Also doing slide mod on BST40 carb. I have a GSXR 1000 can that I can fit as well. So looks like its coming together.

Will be making a Pooratech tool tube then should look at making crash bars.

Okay - so i need to order valve stem seals - though I had some with new gasket set I purchased. 2 days from Suzuki sounds fair to me.
Tomorrow - hopefully I get to Sartor Bros to take parts for coating. It seems motor will be runnig much cooler when done and putting out a nice increase in power.

Seriously thinking to re profile cam as per Pro Cycels spec.

Sounds as if I my have a healthy motor with lots of longevity in it.

No I need to convince wife why I need to keep the DR. Really dont want to sell it.

I may let the XLV750R go...

Ag nee man this is so unfair. :pot:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 31, 2012, 09:39:01 am
Waiting on call from suzuki to collect valve stem seals.

Piston, barrell, head, valves and zorst dropped of for coating at Sartor Brothers for Powerkote of components.

cleaning bike up and its looking nicer each day.

Once assembled - we service shock and we then ready to dyno and looking forward to showing some xr650l's waht Suzuki is made of.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on August 31, 2012, 09:57:01 am
THAT is gonna get INTERESTING !!!

What's your wifes phone number ?  :pot:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on August 31, 2012, 12:45:24 pm
THAT is gonna get INTERESTING !!!

What's your wifes phone number ?  :pot:

It is oh eight three DANGEROUS :xxbah: :xxbah:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 07, 2012, 09:44:59 pm
got parts back from Powerkote. Head assembled on Monday and then we look at putting it all together.

Will try post some pics of the coated parts before assembly.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 08, 2012, 09:09:00 am
 :happy1:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 08, 2012, 09:46:06 am
HKGK!

Also have a 2012 titanium GSXR 1000 SACS exhaust can. don't know if it will help to make more power ( free flowing) but will fit and try. If not right will open and make free flow and repack a bit so noise nice - not too loud as my previous RoadMaster stainless steel pipe was. No one wanted to ride behind me with that pipe. But boy did it sound sweet when you started her.

The excitement is building up now... ::) ::) :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 08, 2012, 03:50:38 pm
I can tell you that my bone stock ( except for Scorch zorst ) 94 DR stays with my ex heavily modified KLR ( 33 nhp to 45 bhp , then I added a Schnitz 685 piston , so say 46 bhp ) , I sold the KLR to a mate and we ended up on an open road WFO blast , and the stock DR even then with a tired bore stayed with that 46 bhp KLR so exactly , that I think you will see 46 bhp on the Dyno ....+/-  24

How's your starting point fueling configured ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 08, 2012, 07:28:19 pm
Running standard jetting, when head was off valves were burning a beautifut marie biscuit colour.


Would like to get dyno jet needle - hoping to dyno with Freeze when ready.


Remember before opening and rehoning bore - Iwas able to beat a modded BMW 650. Don;t know how good that is but bike could see 170km/h top speed and had awesome mid range too. Very quick revving too. And a shit load of compression.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 08, 2012, 09:22:29 pm
" Marie Biscuit Colour " describes well the inside of my Scorch pipe with my squeaky new upper engine and squeaky new totally rebuilt carb running STOCK . So yes , from my side no dire warnings of running lean. These DR's predate the Eurocrats and the main jets are the way a well designed carb engine SHOULD leave the factory. Unlike our brethren on their GS12's , whose uber modern ECU's meter out out PRECISELY the wrong mixture.

I've done many Stage 2 and Stage 3 mods in my time , some with fat horsepower returns , but we have bikes which on paper make 1 bhp less than a KTM640 , I doubt if there is much to gain over a stock setup, without losing out in usability elsewhere. This little voice has me keep my 94DR standard.

Already these older DR's snort and spit in traffic , only just bearable to keep a thumper spinning at 3000 rpm to avoid snatching when stuck behind the inevitable Tazz.

I use my old DR for open road applications , and my '06 DR for city chugging , when I have the choice !

Incidentally , my 06 DR has an additional airbox hole and 150 main , and that microswitch on the throttle at full open is binned , it goes wayyyy better than a stock >96 , but the 94 will STILL leave it for dead !

Interesting how the wilder cam of the 94 uses a slighter smaller jet ! I'm guessing the valve overlap and open valve duration means it has more time to ingest a lungfull of hydrocarbon , so a 137.5 is perfect , where a 140 ( stock) is needed on the shorter induction window, of the newer DR.

Mmm, imagine having your own dyno , when you needed one !

Get rolling soon eh ?

hey I met another dude with an oldtimer DR last week , Norwegian/German guy who flies microlights.

We must all try to get together one day , it would be a helluva hoot.  I need to drag you guys all the way from across the Vaal to my wild place in the Klein Karoo.

Or we should pitch up at a BMW or KTM get-together in formation , and stir  :pot: :pot: :pot:



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 10, 2012, 07:35:17 am
The problem pitching at the BMW or KTM gathering is that when we embaraas them with our old DR's they gonna chase us away.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 11, 2012, 06:26:51 pm
I been playin' : )

I tried lower bars on my ole DR , and hacksawed off the rear subframe and binned the number plate thing , moved the tail light assembly up the fender an inch , and mounted the Super Kak SABS plate direct to the fender , about a kg steel into the bin , and I epoxied closed the resultant naked tube ends under the seat .

But I'd better spray the bars , I'll get arrested for being a sexual deviant , PIENK anodising and Khaki ???  :imaposer: :imaposer: :imaposer: :imaposer:

The lower bars I had 'in stock', had to drill the ends ID out to 13mm to take the barkbuster rawl-plug type thingies, but hey , feels goooood on the bike , not so much begging dog position as elbows-out-aggro position : )

So here's my ole timer now :

(http://i971.photobucket.com/albums/ae199/Veemax/Sept2012.jpg)

and here's the anomaly *grin*

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5760.jpg)



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 11, 2012, 06:37:24 pm
Hey , for fun , here's my Moeg Perd from Apr 2011 with worn out engine , worn out carb , wobbly swingarm , disastrous air filter , buggered cam chain , rusty spoke ends , collapsed fork springs . worn out disk rotor , tired battery, slipping clutch with parts missing, and hidden corrosion .... ja , it's been many, many hours of TLC

Rebuilding old rice burners is time and money , my total "IN" is now R42 000 ! But MAN , does it go well now !!!

(http://i971.photobucket.com/albums/ae199/Veemax/a.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 11, 2012, 06:48:06 pm
Lekker Off Topic , but I'm on photobucket , so noga brag pic sorry  ::)

My "other" DR , which , on this forum topic , gives me the right to say how wonderful the OLD DR is too !  OK OK , I'll go away now  :angel12:

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_5415.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DR BIG 750 on September 11, 2012, 07:23:10 pm
nice ,old DR 's rule also got a few of them in various states of repair
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 11, 2012, 08:47:20 pm
Now if I had room in my garage ....... I'd collect too !

I remember collecting spares bikes back in my XT500 phase ....

I always say if you hafta have ONE bike , the DR650 would be it. Which incarnation would depend where you live. The old DR needs open roads.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 13, 2012, 12:20:04 pm
Hey guys , the oldtimer DR running a BST 40 has a known improvement for some models that use a pilot air jet of 1.3 , by changing to a newer/more recent 1.4 , this apparently goes a long way to improving off-idle carburetion , especially the known "off-idle rich bog"  that, I imagine,  gets WORSE as the carb ages.

I found cmsnl.com offered the 1.4 as a part today , so I have ordered one , along with a larger shipment.

Yesterday my ole DR did duty farm shopping and exploring , in the hands of my mate Ian. His wife took this action pic , whoooo wheeeee , a pre-96 DR doing what it was meant to do !

(http://i971.photobucket.com/albums/ae199/Veemax/332188_10151080622202599_342976508_o.jpg)

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 13, 2012, 03:05:37 pm
Off to get assembled cylinder head from engineer and hopefully run the old girl tomorrow sometime.

Sooooooo Excited.

But my wife - eeeiisshh she not a happy lady at the moment. :laughing4:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 17, 2012, 04:26:09 pm
So bike started without pipe - what a sound.

Then we connected pipe which needs proper fitting and what a sweet sounding Titanium GSXR 1000 pipe. Need to possibly reroute the pipe but it has already been ceramic coated and presents a problem as whole header will nedd recoating. School fees again.

Haven't ridden bike but compression is very strong and throttle response is amazing.

But...........

Seems to be running rich which ot did not do before everything was coated. Looks like we can go quite a bit leaner but will leave upto the dyno test to get right.

Very excited and just want to ride it now - but unfortunately work takes precedence.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 17, 2012, 10:37:28 pm
Lekker news SD !!! So all the bits are there ...now is the time to FORCE yourself to take your time and do things once, right.

My DR showed me a flat tyre yesterday. The thing had a puckered rear tube. Frikkin TracMac amateurs !!!!

All fixed , but new bars vibrate in strange ways ! Don't care , it goes like SNOT !

Keep us posted huh , and take some PICS !!!!!

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 18, 2012, 10:09:37 am
Slight issue locating exhaust correctly and my clever exhaust fitter decided the header was meant to go outside of frame so cut the bend out of my newly ceramic coated pipe.

Ay tog!

So now we need to get a piece of stainless with correct bend to tuck the exhaust in a bit. Will post a pic.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 18, 2012, 08:17:51 pm
Took some pics of where I am at with bike at the moment,

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on September 18, 2012, 08:44:54 pm
 :headbang: :headbang: :headbang: :headbang:

Love the Gixxer pipe , who woulda thought ??? 10/10 for originality !!!

So..... Vroooom ????
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 18, 2012, 09:59:44 pm
Fitted beautifully before we stripped motor but after cutting the bend out we need to mod to get it tucked in a bit. >:(

Sounds quite nice the pipe does, :lol8:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on September 20, 2012, 08:36:47 pm
Took for a ride - accelerates clean from around 2 000rpm and pulls strong. It revs over the redline too easily and needs to be watched. I think after a dyno its gping to be even sweeter with more pull,

Pulls so nively especially in mid range.

So sort exhaust out and off to dyno.

Then a new pooratech tool tube and shock rebuild and we good to go.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on September 21, 2012, 10:21:29 am
Saw this on the www - looks interesting

Trail Tech Voyager Stealth Computer Kit- Suzuki DR650 Models (All Years)

http://www.cruisercustomizing.com/trail-tech-voyager-stealth-computer-kit-suzuki-dr650-models-all-years/part/TRAILT-912-302
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DR BIG 750 on September 22, 2012, 09:05:36 am
Hey Rob good to see you getting active you ready for a ride yet ;)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wild Hearted Son on September 22, 2012, 10:04:00 am
Hey Rob good to see you getting active you ready for a ride yet ;)

almost....... :biggrin:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 12, 2012, 02:32:13 pm
Hey Guys !!!

In the spirit of Continuous Improvement I ordered ( among other bike parts ) from CMS Netherlands  , a 1.4 Pilot Air Jet to replace the 1.3 ...

I also put in 10% beefier HD clutch springs, as despite a brand new clutch, the farker would slip under duress ( high speed , full bore, very big tar bumps )

[btw NEVER try to reuse the clutch cover gasket , I'm dumb and don't listen to myself sometimes, there is a high pressure oil feed under the top edge of the clutch cover that requires proper seal.]

Anyway, I highly highly recommend the 1.4 Pilot Air Jet , even down here at the coast where things are leaner , it improves the bottom end off-idle manner of the bike by a fat margin , I can only imagine what a high altitude and worn carb running a stock 1.3 or early model 1.2 must do ! Yuk !!!

I now no longer dread being stuck in slow traffic as the bike is much more tractable off-idle at small throttle openings.

For those who don't understand pilot systems , the larger air jet lets in more air to the pilot circuit, creating more foam/emulsion around the fuel in transit to the venturi and 'brakes' the fuel flow more.

whooo hooo , I like my bike getting BETTER with time.

 :ricky:

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 12, 2012, 02:39:38 pm
Hey Guys !!!

In the spirit of Continuous Improvement I ordered ( among other bike parts ) from CMS Netherlands  , a 1.4 Pilot Air Jet to replace the 1.3 ...

I also put in 10% beefier HD clutch springs, as despite a brand new clutch, the farker would slip under duress ( high speed , full bore, very big tar bumps )

[btw NEVER try to reuse the clutch cover gasket , I'm dumb and don't listen to myself sometimes, there is a high pressure oil feed under the top edge of the clutch cover that requires proper seal.]

Anyway, I highly highly recommend the 1.4 Pilot Air Jet , even down here at the coast where things are leaner , it improves the bottom end off-idle manner of the bike by a fat margin , I can only imagine what a high altitude and worn carb running a stock 1.3 or early model 1.2 must do ! Yuk !!!

I now no longer dread being stuck in slow traffic as the bike is much more tractable off-idle at small throttle openings.

For those who don't understand pilot systems , the larger air jet lets in more air to the pilot circuit, creating more foam/emulsion around the fuel in transit to the venturi and 'brakes' the fuel flow more.

whooo hooo , I like my bike getting BETTER with time.

 :ricky:



So why didn't you order a few extra? :peepwall:

do you think it will really make a huge difference up here? If so how much and where do I order please? :ricky:

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 12, 2012, 07:24:29 pm
The pilot air jet is a tiny tiny thing , don't have the invoice but it musta cost a Euro *gasp! *

cmsnl.com are great for oldie bike spares

Shipping costs a farken fortune , but it's the only solution I found to buy a loose / new armature for my wifes 1986 Savage, Instead of paying R6400 + for a whole starter motor , ( Suzuki SA ) , I sourced a new armature for Eur 148 , and brushes etc , the pilot air jet was a total afterthought.

In the end I paid R4500 instead of R6400 , but the wifes Savage is so far gone Custom , with new EVERYTHING , I could not be snookered by a toasted commutator.

It all goes to show, if you want a RELIABLE BIKE WITH LONG LIFE EXPECTANCY from an oldtimer , you are not gonna walk away until your input costs have reached R35000 to R45000 for a 650cc !

I am riding up through the Cedarberg tomorrow , on my Velvaglo DR .... rocking !!!!

I'll bore you another time how I nearly nearly destroyed the engine casings today ... HELICOILS ARE KAK KAK KAK KAK KAK things !!!!! Especially when some %@$&^$ hid one and it snags your M6 tap , and the tap breaks off and the whole sh^thouse goes up in flames !!!

What d##s stripped threads on this bike ??? Asshole !

Lucky I got it back from the forces of darkness , but not before tapping 7mm and finally 8mm to recover the blerrie thing ! Sjoe! Thats was CLOSE !!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 14, 2012, 08:43:53 am
Howdy folks, been rather busy crossing oceans the last few months, not much bike time, off next week to cross pond again.

Some bike news, had valves re-seated and new stem seals fitted, while she is stripped will replace rings and then she will be up for sale.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 14, 2012, 09:14:25 am
I have a potential buyer for you , actually, two , down here in the Cape !

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 14, 2012, 09:18:18 am
Tip Of The Day : Don't use Putoline 20W50 , even on a brand new clutch with HD springs , you will get clutch slip under extreme conditions.
( Highway flat out into hectic headwind )

I will go back to low-tech 15W40 HX5 or 10W40 Magnatec or something with a sub-hundred centistokes viscosity @ 100 Deg C

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 14, 2012, 09:27:38 am
Thanks veemax I,ll be in touch once I am back from Tortola, I also had the slipping effect at high revs in top gear, replacing the clutch cured it  :lol8: Used belray thumper oil after replacement clutch and it seemed to work well.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 14, 2012, 09:40:33 am
I have one pal really wanting my old DR bad , he has an R1200GS Adv , we swapped bikes yesterday on the road home from the Cedarberg , I nearly fell asleep on the GS ..... zzzzzzzzzz *yawn* , too disconnected from real biking !

Anyway , Graham is wanting a small agile thumper and I've already sent him this link ! He's in no hurry so it could work out nice.

I've just checked my records , only the odd thin plate/thin disk is in fact new in my clutch ( it was a bastard like so many that fall into the hands of guys working with no manual ! ) , as the stack was all in spec , I used all the existing plates. I hope the Putoline has not 'poisoned' my plates with additives. Anyway , I'll change oil and field test again , it's coming up for a change anyway...

Otherwise , new friction plates all round, like you say.

You selling to buy, or selling due to low usage ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 14, 2012, 09:54:38 am
I am selling to buy, not that the sale money is needed for the new purchase, still a bit undecided if I must sell the DR or have two bikes :ricky:

I have my eye on a Honda Transalp 700 found the DR a bit painful on my long hauls (vibration) it may have been the valve story but my throttle hand swelled up like I had hit a wall, could hardly ride.

I intend to do a Namibia epic next year so sacrifice off road capabilities for comfort and take it easy in the dirt with the Alp is my thinking.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 14, 2012, 02:08:13 pm
I rode an XLV700 with a view to buying. I was very impressed with it as a road bike ( never rode one in the dirt ) . Nice power , smooth and refined, very comfortable. I missed the chance as I have a Sell One Buy One policy and the guy buying my KLR delayed me. I still regret not having owned one yet ! : )

In the end the KLR went and made way for a year long 94 DR overhaul !

Many plusses on the XLV but beware the fuel range, they REALLY cocked that aspect up for us big-sky folks. The rest is a nice package , and they are famous for long life.

I saw a good one in Mpumalanga on gumtree right this am ... *grin*

Here in the Cape we don't have to cross vast distances for good riding , so happy with the mechanical similicity of my DR's young and old.

I wish the VStrom was not so pig ugly , sure rides nice , but it's fugly and soft and squishy and very vulnerable offroad, what a pity.

If Suzuki wanted to make a good bike , make the VX800 into an Adventure Bike ! : ) , shaft and 68 bhp.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 24, 2012, 11:03:22 am
Clutch slipping sorted. A certain person who shall remain nameless had the Plate # 2 's wave ring and wave washer seat ring installed incorrectly . These clutches ( like that on the 650 Savage ) , require very very VERY careful attention to those two rings !

Only by bringing the clutch hub in from the garage and holding it in front of the screen , could I see the fault and understand it !

(http://i971.photobucket.com/albums/ae199/Veemax/Clutch.jpg)

Anyway , I installed new friction plates ( 6 plus 1 special ) with HD springs ( 10% stiffer ) , with fresh 10W40 Magnetec , and headed off to test flat out on the bumpy Cape Point road into a hectic storm South Easter , could NOT budge the plates , yesssssssss , now this bike can boogie flat out.

While feeling Holy , I have installed a brand new disk rotor and pads, the rotor was at minimum thickness, pads nearly dead too.

Right , I think I have run out of things to do with my DR now , just ride it I guess ! : )

The Speedo says 33 323 Miles , or call it 54 000km , and all it's wear parts are NEW. I am all-in at probably R45 000 now

Mission accomplished !

(Which was , essentially, to replace my KTM640Adv , with a simpler , tougher, easier to maintain, similarly powered adventure bike, with no leaky USD forks , no ball crushing seat, no unbalanced engine with a rep for running main bearings, no water cooling to fret over, a steel tank that accepts a magnetic tank bag, no ridiculously expensive parts , a slightly lower seat height for the rough, and an obscure and indefinable brand that makes me immune to the BMW/KTM yawn !!! And did I mention: DOGF^*K reliability )

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 24, 2012, 11:28:37 am
Great! My DR is also now at the 'just ride it' stage. Nothing more I want to do to it, I just need to find time for a nice long dirt trip now.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 24, 2012, 11:37:09 am
Mine is not quite there yet - but it is going on a long ride this weekend hopefully!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 25, 2012, 02:36:19 pm
And in summary : )

(http://i971.photobucket.com/albums/ae199/Veemax/TheToughestAdventureBike.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 25, 2012, 02:58:23 pm
Great! My DR is also now at the 'just ride it' stage. Nothing more I want to do to it, I just need to find time for a nice long dirt trip now.....

Come down to the Klein Karoo for a beer , and some big sky therapy ? I have a wild pace 45 km west of Ladismith , headed there for two weeks, load that DR and run away !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on October 25, 2012, 03:00:36 pm
Soon enough! Busy with a job currently, but when that's finished I *may* be unemployed so I may well take you up on that!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 25, 2012, 05:23:15 pm
I may hang on to my DR long enough to join this gathering, just need to cross the pond first
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 25, 2012, 05:38:28 pm
I cam every close to an XLV700 WC ! Had it lined up as a straight trade for my Bandit, but then the poor bugger fell fowl of a taxi ..... bike not running and the dude very upset. Poor guy, Oh well , I can wait ! Not like I dont have any dualsport bikes in my garage.  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 25, 2012, 05:55:12 pm
They go for a very good price for low mileage models, it just seems sensible for me , reliable , smooth comfy etc, couple of 2L coke bottles for tank range.
If I sell the 650 I may get a 400 for more technical stuff and the 700 for long hauls.
Did you find that Acerbis?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 26, 2012, 07:42:30 am
Yeah thanks mate, Just Tanks appear to stock 'em. I am wondering if it's worth the loss of a magnetic surface though .... mmmm......but 25 L will let me go +500km , useful distance in 'Nam .... ( We once counted on fuel in Leonardville and found none , made Koes with 300ml left , and my riding mates stranded 30 km away high and dry, counting on ME to rescue them ! )

Let me ponder some more ....naturally it will get the fuel stripe / khaki paint + lizard treatment !

Thanks for the link , the other sources seem to have hahahaha run dry !





Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Ganjora on October 26, 2012, 07:52:52 am
Veemax,  what's a '12C socket'?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 26, 2012, 08:22:57 am
VOLTS !!! C and V are keyboard neighbours ! Duh
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on October 26, 2012, 08:27:04 am
I dont know how the Acerbis will like paint, it seems to flex a bit and have almost a "pebbled" surface , much lighter than the metal tank though.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on October 26, 2012, 09:48:31 am
I think I have a working system for plastic tanks , PLAB tested anyway , lasts over a year so far.

600 grit used to break surface , apply THIN dust coat Rustoleum Plastic Primer , leave for a week ....walk away !!!!

Then top coat Velvaglo ... backbone is a Plascon- proprietary self crosslinking enamel that holds up to fuel transit through the polyethylene pretty well.

You could top coat with anything maybe , but I've not tested that.

You might have to strip it and repeat every few years , but so far, for my application its a working solution for a dirt bike.

PLAB shows one smallish bubble under the seat area , is all.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on November 20, 2012, 11:00:20 am
WAT GA HIER AAN DAT HIER NIKS AANGAN NI  :sip: :spitcoffee:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on November 20, 2012, 03:13:03 pm
Bloody reliable DR's is the problem !

Gooi petrol , ry ry ry ry ry ry ry ry ...... ens.

 :ricky: :ricky: :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 04, 2012, 07:47:09 am
Does anyone know which wheel bearings the DR takes?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 04, 2012, 08:16:32 am
Can't help sorry , redid mine but my little black book shows I didn't write down the number. I always shop with a sample. Super common bearing your nearest bearing guy will definitely have it though.

You gotta have two bikes , one under surgery and the other one the rapid procurement scoot !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 04, 2012, 09:20:12 am
Can't help sorry , redid mine but my little black book shows I didn't write down the number. I always shop with a sample. Super common bearing your nearest bearing guy will definitely have it though.

You gotta have two bikes , one under surgery and the other one the rapid procurement scoot !

OK, fortunately have the sample!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 13, 2012, 08:58:57 am
I changed the front wheel bearings (well Runner did). There was a problem since one of the bearings was an unobtainable size (16mm wide), so two 8mm bearings were used in its place

Old on the left, new on the right
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 15, 2012, 09:16:18 am
DB9 you rolling ?

Guys , lets look way ahead to 2013 , whose bok for a gathering ?  :3some:

My DR is now with nothing left to do on it but riiiiiiiddddeeee !!!!

Wildcoast , you still with us ?

Dammit these bikes are awesome , once sorted for worn out parts , they beg for another lifetime of thrashing.

Any bright ideas for improving on the seat for the long haul ? I've 'shaped' mine , but it doesn't come close to the Sargent seat on my newer DR.

Oh, I have to brag, my carb is SO sorted now , that it can start on the choke , be left to idle like a fuel-injected bike while I put on my helmet and gloves , then transitions to an idle , all without touching the throttle.

That bitch carb taught me a life lesson in tenacity.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 17, 2012, 08:14:53 am
Check this out over at the >96 DR thread ! I'll put it here to save you the trip :

From ADVrider:

Another milestone for the mighty DR. Clocked up 400,000 klm,s last week and the old girl is still going strong, not bad for an 05 model. She has had a few niggles along the way and quite a few new and used parts but hey i'm not complaining. The last rebuild at 360,000 was a biggie, it started jumping out of first gear so replaced all the driven gears, the barrel was worn out so a secondhand barrel and new piston and rings went on and splashed out on some original clutch plates and steel plates with new springs,i tried a EBC clutch kit but all it wanted to do is slip so was not impressed,originals lasted 170,000klm,s. Cam chain got replaced at 100,000 klm intervals and cylinder head and valves never touched apart from valve stem seals at about 300,000 klm,s It is a courier bike and gets ridden everyday in lovely Melbourne traffic rain hail or shine and thats in just one day Hot days cold days you name it,so it not an easy life but she still starts every time and still has the original starter motor. Fitted out with a few farkles like a IMS tank, pro tapper bars, staintune exhaust, b+b bashplate, had the suspension stiffed up with heavier springs and had to fit a tm40 because original carby decided not to play ball anymore. And it still has the original seat,it has been recovered because the stitching split but the foam is all stock, the only time it gets a bit painful is when it gets hot and you sweat or when the crutch gets wet from the rain. Best bike ever Suzuki
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 18, 2012, 08:41:04 am
All that from a single cylinder motor bike. Only other bikes that regularly clock these miles are the Hondas!

Would like to see a KTM do these km's trouble free.  :pot: :peepwall:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 18, 2012, 08:50:16 am
Ja, main bearings do 400 000 ?? Pah LEEEEEZE !!!!

 >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on December 18, 2012, 09:00:18 am
Ja, main bearings do 400 000 ?? Pah LEEEEEZE !!!!

 >:D

Stir the pot my lad! :laughing4: :laughing4:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 18, 2012, 11:02:59 am
Hey Veemax, what's the bests paint to use to paint your exhaust header pipe? Will rattle can heat resistant paint work? Or is there some specific paint you need to use? I have my header off to grind the weld out of the front end of it. Its quite a blob of metal in there, at least 2-3mm thick.

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Ganjora on December 18, 2012, 11:14:53 am
sure its not stainless steel?
polish it up...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 18, 2012, 11:43:08 am
I think it is, When I have removed the ceramic coating (i.e compacted and baked mud), I'll sand and buff it should look cool. I've also got one of these header protector sleeves to put on, watch this space.. ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 18, 2012, 12:05:35 pm
What they said !

UHT doesn't work for long , it's better not to go down that road.

Did with the wifes mild steel headers on an XLX350R with UHT and regretted not copper/nickel/chroming the freakin thing , or better, Powercote.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 18, 2012, 06:22:06 pm
Cleaned up the header pipe with a wire brush on the drill, then polished it with a buffing wheel. Came out quite well I think. Does look a but on the bling side though. Header pipe protector fitted as well. I took about 1mm off the weld inside the pipe and sanded it smooth. Might make a difference?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 18, 2012, 06:33:38 pm
The weld work often makes enough diffs to feel ! But make sure you don't have that devil of a carb full-open-timing-retard-switch or there'll be no point.

Suzuki employed some twatwaffle who put timing retard switches on a lot of bike for countries the ASSUMED to have poor quality gas , kills the top end. no doubt it's the same twatwaffle who invented what is infamously known as the Marauder Mystery Module , that stops cruisers of that name from cranking.

Both these devices you cut orf , and tradition has it, you fling in your neighbours yard to get eaten by his lawnmower. :lol8:

That pipe looks pretty cool , but you got to dirty it in line with the rest. Let us know if it doesn't rust !  :eek7:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 18, 2012, 06:45:16 pm
Ja, I hope it is in fact stainless!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 18, 2012, 06:50:41 pm
Could be a minor issue if the Mayans were right  :bom: :bom:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 18, 2012, 06:54:29 pm
Is there supposed to be a clamp between the header and the zorst? I don't have one? And are the only 2 attachment points on the head and 1 bolt on the rear? Seems a bit flimsy to me? (Although its been like that since I got the bike)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on December 18, 2012, 10:35:30 pm
Ditto, seems to work !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on December 19, 2012, 09:18:12 am
Ditto, seems to work !

I think I may put a clamp there, just to strengthen it a bit.

Regards,

Steve
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on December 23, 2012, 05:53:26 pm
Yeah Veemax, still here, just in Puerto Rico at the moment, should be home by Christmas eve, DB9 I used a rattle can heat treatment on my header pipe, seemed to work okay, nice thing is it's cheap and easy to re-apply, just make sure "bokkie" is going to be out for a few hours when you bake the thing in the oven  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 08, 2013, 06:56:36 am
Must share this !

I went for a nice ride yesterday with a pal aboard a range-tank kitted XR650 with impressive sounding Scorch pipe. This guy can riiiiiide , balance-wheelie master , and he carries corner speed on gravel most fear to follow. He is one of those nutcases that did the Amageza. Needless to say he is much younger than me too.  ::) , and I can say for sure that when you are over 50 , your balls shrink.

But all that aside , my bone stock 94 DR left that XR behind , in both acceleration and top speed , by a meaningful margin.

And he was getting 17 km per litre and I was getting 21 , despite some aggressive riding.

I put this down to my rebuilt, otherwise brand new carb , and that legendary Suzuki patented TSCC engine design.

His bike SOUNDS more powerful , but perhaps his Scorch's larger dia baffle is causing full bore 'reversion' ( standing wave causing trouble ) ????

Do not under estimate your ole DR , these robust oldtimers are maybe 1 bhp off the KTM640 , I say this having owned both.

When the DR comes on the cam from 5000 to 7000 rpm , it provides a window of oooomph that leaves other thumpers gasping like fish out of water.

I may curse the old DR snatch and cough below 3000 , but the compromise melts away when you're hangin' on the cable  >:D >:D >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 08, 2013, 09:22:25 am
Testify!

I finally got round to cleaning my bike (sort of). I fixed a hole melted in my side cover with some thin expanded metal, hopefully that will be strong enough. I also got an ATV tank bag for odds and ends. Nice that the petrol cap is accessible compared to most tank bags that cover it.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2013, 06:17:47 am
I have all my goodies assembled finally, start to assemble my bike today, new rings, gaskets and urgraded head  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on January 09, 2013, 06:50:06 am
Cool, sounds good.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2013, 07:58:32 am
I have all my goodies assembled finally, start to assemble my bike today, new rings, gaskets and urgraded head  :ricky:

Make sure you put a new viton o-ring on the oil return pipe it's a real SOB for leaking !!!!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 09, 2013, 09:32:21 am
Ill just use the age old yachts mans high temp silicone fix  :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2013, 11:15:41 am
I used a locktite high temp silicone on squeaky clean metal but the oil STILL got past .... grrrrr ....... !!! However, after many heat/cool cycles it seems to settle in to a slow spreading weep. And only if you work it HARD.

The OEM O-ring is 21 x 4 , I tried a 21 x 5 but could not get it in (  >:D ) .... need a 4.3 to 4.5 in Viton but it does not appear on any tables and Bearing Man could not help me.

Maybe you get lucky and perhaps the sleeve area in your bikes head is in better shape ? It's the ONE fault of this old design in my opinion.

The manual says use grease ...

Fork It I was even tempted to try epoxy on a non-return basis ! But it's a real hot spot , combined with thumper vibes it's a challenge.

Just giving you the heads up to do it right the first time , because no hombre in his right mind will disturb a newly assembled mill for a minor oil weep.

Every old DR I've seen seems to suffer the same minor ailment , it's no show stopper but the smell of hot oil makes the bike seem OLD , when it's not !

The Brit Bike restorers page says to try this outfit for a custom Viton 21 x 4.3 , but I have not tried begging there yet. Feel foolish asking for one mickey mouse seal !

•   Seal Services
•   4 Pinelands Business Pk, 4 New Mill Rd, Ndabeni, Cape Town
•   Tel: (021) 531-6651
•   Fax: (021) 531-3958
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Het-Jou on January 09, 2013, 11:27:53 am
Wright seal and plastics in Parden Island, Cape Town will make you a Viton O ring of what ever size you require
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2013, 11:59:15 am
Het Jou jy's hin GOEN !!! :3some:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 09, 2013, 01:03:42 pm
I have all my goodies assembled finally, start to assemble my bike today, new rings, gaskets and urgraded head  :ricky:

Make sure you put a new viton o-ring on the oil return pipe it's a real SOB for leaking !!!!

Agreed :'(
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on January 09, 2013, 06:12:20 pm
EISH Freewind pis olie bo iewers van die rockerbox se kant af wonder of dit ni dalk daai oring is wat lekr dan loop dit langs die kant af het n R200 rand se mercedes gasket maker gebruik om rockerbox te seel...
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 09, 2013, 08:30:46 pm
Links kant lek ?  The breeze can verneuk you , gotta clean it and do a short squirt to find the SOURCE !

I also had a tappet cover ( exhaust side ) leak but careful attention to the faces I found a high spot .... flat file and ooopah fixed.

These oldies have been around a few owners so you have to ask yerself what bliksem worked on it before !

Half the threads on my clutch cover were damaged , I even had to drill one to thread to M8 to recover it.

Lucky it's not a KTM so there is enough meat for a proper and permanent fix ...

Trust NO _ONE !!! Doen dit SELF , doen did REG , doen diet EEN KEER.



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 10, 2013, 12:02:27 pm
Links kant lek ?  The breeze can verneuk you , gotta clean it and do a short squirt to find the SOURCE !

I also had a tappet cover ( exhaust side ) leak but careful attention to the faces I found a high spot .... flat file and ooopah fixed.

These oldies have been around a few owners so you have to ask yerself what bliksem worked on it before !

Half the threads on my clutch cover were damaged , I even had to drill one to thread to M8 to recover it.

Lucky it's not a KTM so there is enough meat for a proper and permanent fix ...

Trust NO _ONE !!! Doen dit SELF , doen did REG , doen diet EEN KEER.

 :thumleft:



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 23, 2013, 04:51:28 pm
Barrel on, head on, just need to buy some consumables and she will be running by the weekend, just bought a 650 Alp. To sell or not to sell  :-\
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on January 23, 2013, 09:06:01 pm
In case you want to sell it , let me tell you a short story ....

My mate , owns a software business, looks out his window last Monday ...thinks....fukkit.... ek's nie LUS om te werk nie .....let me go ride....who do I know...... oh yes , that retired ou vroetel vark !!!

Next thing he is on his XR650 and me on my oldtimer DR heading for the backroads .... his bike has all the bells and whistles.... Bosson pipe and jet kit....tank....bash plate....his bike is so hardcore he even has his Amageza competition number on it ..... that cost him a fractured colourbone .....so you get it right ? Hardcore dude. He can wheelie all day if he choses ...

He can't stay with me off the line , and fades from my mirror on top end. Good night, nurse.

My '94 bone stock DR 650 leaves his XR for dead



Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on January 26, 2013, 08:37:26 am
I also play with them XR650L.

Generally I ride behind but at times I let them go and then haul them in. Acceleration on my bike is also good.

I love my DR even more than my AT.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Wildcoast on January 26, 2013, 04:38:08 pm
Putting my bike on the market for a few days, it's tying me up here in East London, I need to leave town next week , have not finished assembly as time is against me , if I don't sell it no train smash will put it into storage for some other day , 15k as is , has papers etc
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 11, 2013, 01:37:40 pm
Ja, I hope it is in fact stainless!

Turns out, its not.. Anyways, wirebrushed all the rust off and sprayed with about 10 thin coats of manifold paint. Lets see how that works. I'll put it back on when I've found some clamps to hold the exhaust can more firmly in place.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 11, 2013, 02:04:03 pm
Not s/s eh :< ? My bikes 20 next year , whatever OEM coating that is , WORKS !  Ceramic ?

I need to ride faster , no chips in it yet ...

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on February 11, 2013, 02:15:40 pm
Not s/s eh :< ?

I can be a bit caustic sometimes.......  >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 11, 2013, 03:00:02 pm
 ;D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on August 20, 2013, 11:05:23 am
Guys can you confirm whether this tail light lens from my DR750 is the same as a pre 95 DR650? If so, anyone have a spare they'd like to sell?

Cheers
Ian

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on August 20, 2013, 11:09:34 am
Guys can you confirm whether this tail light lens from my DR750 is the same as a pre 95 DR650? If so, anyone have a spare they'd like to sell?

Cheers
Ian



Doesn't look like it. Try Suzuki for the parts, they got a 3rd gear and a rear light lens for my '91 DR so they may have one for your DR750?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on August 20, 2013, 11:14:40 am
Thanks. Suzuki dealership here is so useless you'd have more luck getting Suzuki parts from the Yamaha dealership.

Just saw the wheel bearings you changed. I had the exact same problem and solution so it seems the front hubs are at least the same!

Cheers
Ian
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on November 07, 2013, 10:09:23 am
Has anyone had problems with the balancer chain & tensioner mechanism on a DR600 / early DR650?
I'm working on a SN41 with indicated 60odd thousand MILES :o Starts fine (after I adjusted the automatic decompressor properly), runs fine but is a bit mechanically noisy and I think it might be the balancer chain making a racket?
I just can't remember if the tensioner must be serviced on a regular schedule and my DR600 service manual was borrowed out never to be seen again some time in the 1990's ::)

Here's a good link btw with pictures and schematics but it does not state if it's scheduled maintenance?
DR600 & DR650 (up to SP45) balancer chain tensioner (http://www.advrider.com/forums/showthread.php?t=372751)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on November 07, 2013, 10:28:58 am
Somewhere on this thread is a link to download the service manual.

Here : http://www.dreamlodge.co.za/1990-1995_DR650_Service_Manual.pdf (http://www.dreamlodge.co.za/1990-1995_DR650_Service_Manual.pdf)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on November 07, 2013, 11:52:22 am
That system looks identical to the one on the DR750 (SR41). On the 750 it should be adjusted every 12 000km just by loosening the bolts and letting the tension of the spring take up any slack. The mechanism itself needs no maintenance although I suppose it's not impossible that the chain could lose some tension over the years. I just feel the tension of the chain with my finger afterwards to make sure the tensioner has done it's job.

Ian

 
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on November 07, 2013, 12:08:25 pm
In 92 the DR800 manual gives a slightly different procedure. The tensioner system is the same so this is possibly a better way to do it for the earlier models as well.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on November 13, 2013, 08:45:51 am
It's definitely better to do the chain tension with some gentle help for the tensioner mechanism as shown in the updated procedure.
Thanks for posting.

The 600 is starting fine & first kick now (after adjusting the auto - decompressor). Not that it would not have other niggles ::)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on November 13, 2013, 08:49:57 am
I have a spare set of steering head bearings to fit both SN41 (DR600) and the very first DR650 (SP41) OEM upper bearing (the quirky angular contact axial ball bearing) and a generic lower tapered roller with shaft seal. R600. 2/3 of OEM price. Specially sourced, not available over the counter.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Sandeater on November 19, 2013, 08:34:22 pm
Hi guys, i need help please! My son has a  1986 DR 600 and today he broke the kickstarter. Every body tells me i will not get one but im shure there must be one somewhere. Who would be the best person to contact?  Any help would be appreciated.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: chopperpilot on November 19, 2013, 08:53:05 pm
Hi guys, i need help please! My son has a  1986 DR 600 and today he broke the kickstarter. Every body tells me i will not get one but im shure there must be one somewhere. Who would be the best person to contact?  Any help would be appreciated.
Can't help you with the kickstarter. (Kickstarter or the shaft?) It's however important to determine why it broke? Decompression not properly working maybe? I know zip about these bikes. Sure lecap will advise soon. :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Sandeater on November 19, 2013, 09:06:58 pm
Hi Chopperpilot, the shaft is ok but the splines on the kickstarter are almost worn away. I can see that the kickstarter has been welded before, i think the metal is old and fatigued.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Sandeater on November 19, 2013, 09:11:43 pm
Hi Chopperpilot, the shaft is ok but the splines on the kickstarter are almost worn away. I can see that the kickstarter has been welded before, i think the metal is old and fatigued. It broke at the botom where it slides over the shaft, you can say the part that clamps onto the shaft.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: chopperpilot on November 19, 2013, 11:10:48 pm
Hi Chopperpilot, the shaft is ok but the splines on the kickstarter are almost worn away. I can see that the kickstarter has been welded before, i think the metal is old and fatigued. It broke at the botom where it slides over the shaft, you can say the part that clamps onto the shaft.
Eish! Hopelik sal die ander Honde kan help! Wees net geduldig met jou soektog. Jy sal regkom! :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on November 20, 2013, 09:21:44 am
26300-14A03 Lever Assy, Kick Starter DR600 1986 (SG)
Available.

Will cost something around R1k

I replied to the other thread. These bikes start VERY easy and without any effort as long as the decompressor cables are adjusted correctly and as long as you follow procedure when kicking.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: chopperpilot on November 20, 2013, 12:41:17 pm
26300-14A03 Lever Assy, Kick Starter DR600 1986 (SG)
Available.

Will cost something around R1k

I replied to the other thread. These bikes start VERY easy and without any effort as long as the decompressor cables are adjusted correctly and as long as you follow procedure when kicking.
There you go Sandeater! :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 24, 2014, 06:27:56 am
Keeping the thread alive as not been here in a long long time.  :bueller:

Here is a pic just to say my 94 DR just keeps on keeping on , the Toyota Hilux With No Aircon of motorcycles !!!

Recent hectic floods in the Anysberg area of the little Karoo meant destroyed roads and no access to my land there , so I took my oldtimer DR which got me through to inspect my bush camp there , which had survived.

When it hits the fan you want a low-tech workhorse that you can trust , the pre-96 DR is one helluva tough bike, and a restored one is a lifer , don't ever sell such a useful tool !

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_0314_zps27e15ef9.jpg) (http://s971.photobucket.com/user/Veemax/media/IMG_0314_zps27e15ef9.jpg.html)

(http://i971.photobucket.com/albums/ae199/Veemax/IMG_0326_zps8d7a762b.jpg) (http://s971.photobucket.com/user/Veemax/media/IMG_0326_zps8d7a762b.jpg.html)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on February 24, 2014, 08:00:28 am
HEY MR Vee where you been long time no see...

 Goeie werk bly daai Army Bike van jou loop nog  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on February 24, 2014, 08:37:35 am
Loop soos hin mielieboer se trekker ja !   Ride it like I stole it. Flipping boring, nothing ever needs fixing. Wait, that's a lie , I changed the tail light bulb last year.   :ricky: :ricky: :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Torque Curve on June 04, 2014, 12:08:32 pm
So I'm also kicking my side stand out in this here parking lot. I recently bought a 1985 DR600 for the tidy sum of R13k. I drove from PE to Bellville to collect it so total purchase price is really R15k.
The speedo drive packed up at 78000km! and the previous owner probably added another 15k to 20k km's. The bike was in daily use, starts easily and everything except the hooter switch works.
The only mechanical repair I am doing at this stage is to replace the valve stem seals because the exhaust side ones weep heavily onto the stems. I pulled the head and barrel: valves and seats look very good, the rings are still within spec, but close to wear limit. Play on big end is 1.2mm of allowed 3mm.


Thus far I have replaced the steering head bearings, fork oil, repainted frame and triple clamps, cleaned and repacked swing arm and full floater bearings and replaced air filter. The end-can is badly rusted and has been repaired too often and the header pipes need a serious clean up.
The pic is how I got it, but in time it will look clean and new. Once it is clean and runs sweetly, I'll maintain and replace as required. The aim is to have a dependable and affordable adv bike/commuter.

Any other DR600 kickstart riders around?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on June 04, 2014, 12:25:13 pm
what n beauty die fred is ma still jong hier gan nie iets aan die bikes breek nie en almal  :ricky:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Torque Curve on June 04, 2014, 06:17:22 pm
what n beauty die fred is ma still jong hier gan nie iets aan die bikes breek nie en almal  :ricky:

Ja, die toestand van die motor met bykans 100k km op is nogal gerusstellend. Ek ding ek gaan baie lief raak vir die ou girl!
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on June 04, 2014, 08:39:55 pm
So I'm also kicking my side stand out in this here parking lot. I recently bought a 1985 DR600 for the tidy sum of R13k. I drove from PE to Bellville to collect it so total purchase price is really R15k.
The speedo drive packed up at 78000km! and the previous owner probably added another 15k to 20k km's. The bike was in daily use, starts easily and everything except the hooter switch works.
The only mechanical repair I am doing at this stage is to replace the valve stem seals because the exhaust side ones weep heavily onto the stems. I pulled the head and barrel: valves and seats look very good, the rings are still within spec, but close to wear limit. Play on big end is 1.2mm of allowed 3mm.


Thus far I have replaced the steering head bearings, fork oil, repainted frame and triple clamps, cleaned and repacked swing arm and full floater bearings and replaced air filter. The end-can is badly rusted and has been repaired too often and the header pipes need a serious clean up.
The pic is how I got it, but in time it will look clean and new. Once it is clean and runs sweetly, I'll maintain and replace as required. The aim is to have a dependable and affordable adv bike/commuter.

Any other DR600 kickstart riders around?

Looks like my 650 kicker, but I have a single pipe header.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on June 05, 2014, 11:59:00 am
I agree - looks similar to my kick start too.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: pielas on June 25, 2014, 06:56:08 pm
I just need some advice please. I have not read through the whole 53 pages yet, but it seems you guys really like the pre 96 DR's

I have an opportunity to buy this bike for R3500, and would like some advice. Apparently only the piston, sleeve & conrod needs replacing. Except for the engine everything is very well looked after and in good nick. I have a 2008 DR 650, and really like the simplicity and honestness off the thumper.

Are parts for these readily still available from Suzuki? and do you think this is a good buy?

(http://i.imgur.com/zIXBWlk.jpg)

(http://i.imgur.com/7UDXGYH.jpg)

(http://i.imgur.com/DqsS0jk.jpg)

Any advice here will really be appreciated.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on June 26, 2014, 06:41:18 am
Eben, I would go for it. I haven't had any problem getting engine and gearbox parts for mine, and there are aftermarket parts still available on procycle. Ask a suz dealer to look up if the parts are available and then take it if they are. The only part I didn't manage to get from Suz was a side cover.

That model you have there has the 21l tank and a proper luggage rack, unlike your 2008  :P.

It looks the same as the model I have:

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on June 26, 2014, 07:43:20 am
Guys I'm looking for a rear wheel with disc, rear brake caliper and master cylinder. Anybody have a bike being stripped for spares?

Thanks
Ian
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: fredda on June 26, 2014, 12:05:08 pm
Guys I'm looking for a rear wheel with disc, rear brake caliper and master cylinder. Anybody have a bike being stripped for spares?

Thanks
Ian

Hi Ian, I don't know if this is the same bike that pielas want to buy, but this guy is stripping his DR for spares.
http://www.gumtree.co.za/s-motorcycle-parts-accessories/dr+650/v1c9215q0p1 (http://www.gumtree.co.za/s-motorcycle-parts-accessories/dr+650/v1c9215q0p1)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on June 26, 2014, 12:38:51 pm
Thanks. Might be the same bike. But I've asked the seller for details in case it's not.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on June 26, 2014, 02:58:43 pm
Ek het vi jou n wiel pm my jou nommer
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on June 26, 2014, 08:57:24 pm
Thanks. PM sent. But just to confirm; must be a pre 94 DR650/600. Later dr650's are different.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on June 27, 2014, 01:07:31 pm
Still looking for rear wheel and brake parts.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on July 30, 2014, 08:21:40 pm
Oh no, disaster !!!!!!!!!!!!!!!

Something FAILED on my 94 DR 650

I had to solder a new wire to the tail light , vibration loosed the solder joint !!!!

AT LAST SOMETHING TO WORK ON !!!!

My 94 DR is as boring as my flippin Hilux 4x4 , nothing ever goes wrong.

*yawn*

 >:D >:D >:D >:D >:D >:D
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: zetman on July 30, 2014, 08:24:21 pm
Ooops julle ma stil op di fred
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Biker Hippie on May 18, 2015, 10:53:00 pm
Howzit .

Please can someone help.

I scored an old beauty DR600 s 85model that was sitting on a farm forgotten.
So i got it and she is not in too bad nik. Battery replaced and handlebars and a basic service and she is starting.
I am having a few issues, once started and riding there seems to be a problem its like its reving but not getting full acceleration.
I mean she goes but it feels flat or a flat spot. Im only a beginer when it comes to mechanical stuff.
I have read a few articles online, and i think tom i will clean out petrol tanks and then check the carb out.
I hope i can get it firing right, if anyone can help with suggestion i would appreciate it alot.

Thanx ahead.

G
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 19, 2015, 08:25:21 am
Hey shot on getting that solid oldtimer ! I'd start with a complete carb take-down. I've restored many old thumpers and the carb is INEVITABLY going to be a problem. How is the compression ? The state of the air filter ? If it's got a well maintained air filter you'll be in luck. Most old thumpers I've bought have vrot airfilters, and subsequently worn cylinders ...and carb slides and slide guides. Start with the carb and take pics of the slide and slide guide lets see how much movement is there ....  if it's a BST40 carb they're a bitch to set up, but take heart, they can be totally made new if you know where to shop for the plastic inserts ....
Title: Re:
Post by: Biker Hippie on May 19, 2015, 10:51:30 am
Hey Veemax shot for the reply
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Biker Hippie on May 19, 2015, 10:53:26 am
I'll get on that. Compression feels good
 (http://images.tapatalk-cdn.com/15/05/19/b82cf421863fb7e8864d538744f11955.jpg)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 19, 2015, 11:10:10 am
Looks like its in good nick, apart from a few small cosmetic problems. I have the opposite problem to you. Everything is fine but no compression. One day I'll get a chance to get that sorted out, but I've been working on an even older thumper lately.....
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on May 19, 2015, 11:47:52 am
Drop that in a bike chassis for the ultimate non-wheelie !
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SmuGS on May 19, 2015, 11:51:18 am
I'll get on that. Compression feels good
 (http://images.tapatalk-cdn.com/15/05/19/b82cf421863fb7e8864d538744f11955.jpg)

Hey that looks almost like my bike..

http://www.wilddog.za.net/forum/index.php?topic=169621.0 (http://www.wilddog.za.net/forum/index.php?topic=169621.0)
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on May 19, 2015, 12:07:51 pm
Drop that in a bike chassis for the ultimate non-wheelie !


You could drop that THROUGH a bike chassis, only weighs about 350kg.... (and all of 8 horse power)
Title: Re:
Post by: Biker Hippie on May 23, 2015, 12:27:41 pm
Read your link smuggy wow. Inspired thank you. I went for a ride today started first kick but after 5 min ride it just dies and I can't start again. I'm going to take tank off and check the carb
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 16, 2016, 05:08:27 pm
Just wondering if jetting the carb for sea level has been covered in thread.

Do I need to rejet my bike that was set up for Gauteng altitude?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Veemax on March 17, 2016, 08:43:48 am
Check yr carb is a 12EF // 411 , ID on left side

For sea level : =

You should have a 6F10 needle 691-y2 nozzle and 137.5 main jet

Pilot should be 52.5

Pilot Air is a 1.3 stock but 1.4 is better and I wish I had a 1.5 because that would be better still , the stock setup (1.3) is prone to off-idle rich bog at full operating temp

It must have been an icy cold day in Japan when they chose a 1.3,  cos its wrong !!!

If your slide and slide guide is worn no amount of jetting will overcome a crap running older DR ! Passop !

Hope this helps ?

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: IanF on March 18, 2016, 09:41:40 pm
I'm looking for a rear caliper bracket for a pre 94 DR650. I've got all the parts I need for a rear disc conversion on my DR750, just missing this bracket.

Ian

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Gérrard on March 28, 2016, 08:07:01 pm
I'm looking for a rear caliper bracket for a pre 94 DR650. I've got all the parts I need for a rear disc conversion on my DR750, just missing this bracket.

Ian



Check with Lecap. He might have old DR spares.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on March 28, 2016, 09:05:58 pm
Check yr carb is a 12EF // 411 , ID on left side

For sea level : =

You should have a 6F10 needle 691-y2 nozzle and 137.5 main jet

Pilot should be 52.5

Pilot Air is a 1.3 stock but 1.4 is better and I wish I had a 1.5 because that would be better still , the stock setup (1.3) is prone to off-idle rich bog at full operating temp

It must have been an icy cold day in Japan when they chose a 1.3,  cos its wrong !!!

If your slide and slide guide is worn no amount of jetting will overcome a crap running older DR ! Passop !

Hope this helps ?



Bike runs well, carb responsive but I want to be sure I am set up properly for coast.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on May 11, 2016, 05:10:41 pm
Does anybody have a link to workshop manual for 1994 DR650. The dreamlodge link on first post is not working?

Any assistance would be welcomed. :thumleft:
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: DeepBass9 on July 11, 2017, 01:16:26 pm
Anyone still here?  >:D

So I import a 25l (6.6 Gallon) Acerbis tank for my DR and it turns out that it doesn't fit! Its for '92-95 DRs and mine is a '91. Bugger.

If anyone wants it, make me an offer. Its brand new, unused. : http://www.justgastanks.com/suzuki-dr650-acerbis-gas-tank-1992-1995/

I would like to get my money back if possible.....

Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: lecap on August 11, 2017, 11:36:28 am
Anyone here can PM me contact details for Veemax?

Any one has tightening torques for an SP43 cylinder head. Or a WORKING link to a manual?
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: benreaper on October 27, 2018, 09:37:27 pm
Hi everyone, I'm looking for a coil for my 1986 DR600s. Haven't tried the agent's as I'm scared of what they might say.

A mate of mine who owns a motorcycle shop reckons he can fit a coil from a Chinese twin cylinder bike for me as his done this before on a DR600, but I'd first like to try and get an original part before resorting to this.

If anyone can point me in a direction to potentially source this part it would be greatly appreciated.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: SuperDavexlv750r on October 28, 2018, 12:49:24 pm
Hi everyone, I'm looking for a coil for my 1986 DR600s. Haven't tried the agent's as I'm scared of what they might say.

A mate of mine who owns a motorcycle shop reckons he can fit a coil from a Chinese twin cylinder bike for me as his done this before on a DR600, but I'd first like to try and get an original part before resorting to this.

If anyone can point me in a direction to potentially source this part it would be greatly appreciated.

I somehow don't think that you will find one at the Agents. Perhaps the later coil DR coil is the same if - not your other option is not a bad one necessarily.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: benreaper on October 28, 2018, 01:10:04 pm
Hi everyone, I'm looking for a coil for my 1986 DR600s. Haven't tried the agent's as I'm scared of what they might say.

A mate of mine who owns a motorcycle shop reckons he can fit a coil from a Chinese twin cylinder bike for me as his done this before on a DR600, but I'd first like to try and get an original part before resorting to this.

If anyone can point me in a direction to potentially source this part it would be greatly appreciated.

I somehow don't think that you will find one at the Agents. Perhaps the later coil DR coil is the same if - not your other option is not a bad one necessarily.
The DR600 was a twin spark motor, so the coil has two wires leading to two spark plugs whereas the DR650 is a single spark plug motor/coil.
If I can't find something I might just go the "Chinese option" at first and still look around for a original replacement part over time.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: Mr D on October 28, 2018, 01:25:56 pm
Is this the one?

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F362233355204

Pasting link from my phone so hope it works.

If not urgent could assist in getting it here early January.
Title: Re: Older DR 600/650 thread (Pre mid 90's)
Post by: benreaper on October 28, 2018, 07:12:54 pm
Is this the one?

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F362233355204

Pasting link from my phone so hope it works.

If not urgent could assist in getting it here early January.
Looks to be the right part yes Mr D, I'm not exactly sure how buying on EBay works though. Are you currently in the U.K.?

I haven't started the bike all week so quickly tried it this afternoon. Starts perfectly first kick. I let it idle for some time till it cut out. Started easy again after that. By now the engine was propper hot and I disconnected the suppressors individually to check for spark. Spark is strong jumping from about a 10mm gap and the idle speed only dips a little with only one plug connected.
So with no issues popping up in the driveway I headed out for a short spin around the burbs and a quick loop in the bush then headed home. The bike didn't stutter or cough once and even as I got home it idled perfectly.
Don't you just hate electronic problems!
Will go for a long ride next weekend to see what it does when it has to labour at speed and up a few hills.