Author Topic: Older DR 600/650 thread (Pre mid 90's) (Read 33510 times)

Veemax · « **Reply #80 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

!!!!!!

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.

SuperDavexlv750r · « **Reply #81 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.

Wild Hearted Son · « **Reply #82 on:** October 23, 2011, 05:55:41 pm »

Quote from: 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.

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...

Veemax · « **Reply #83 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.

Veemax · « **Reply #84 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 ....

DeepBass9 · « **Reply #85 on:** November 03, 2011, 10:04:10 am »

Awesome!

SuperDavexlv750r · « **Reply #86 on:** November 03, 2011, 12:19:45 pm »

Beautiful

Veemax · « **Reply #87 on:** November 13, 2011, 06:52:34 pm »

My wife decided my bike makes a nice change from painting ceramic coffee mugs ....

Wild Hearted Son · « **Reply #88 on:** November 14, 2011, 08:06:51 pm »

very nice too

Veemax · « **Reply #89 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.

Wildcoast · « **Reply #90 on:** December 01, 2011, 02:29:02 am »

Geez Veemax your bike looks friggen awesome, cant wait for time to start on mine.....

madmike999 · « **Reply #91 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

Veemax · « **Reply #92 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.

Veemax · « **Reply #93 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.

Veemax · « **Reply #94 on:** December 12, 2011, 05:02:18 pm »

And a last side shot before it goes for surgery ...

Veemax · « **Reply #95 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

Wildcoast · « **Reply #96 on:** December 14, 2011, 03:58:50 pm »

So Motolab now has the spec and we can all order this stuff if needed?

Veemax · « **Reply #97 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 !

Wildcoast · « **Reply #98 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?

Veemax · « **Reply #99 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 ?