Author Topic: DR-650 Build Thread Part 1 (Read 130844 times)

Flyin6 · « **Reply #500 on:** August 03, 2016, 09:26:52 AM »

I fussed with this thing all afternoon, and by night fall, wasn't any further along that I was when I began.

Now keep in mind, the thing was jetted from ProCycle for the header and air box mod and was running strong just before the backfire, so it's not jet size or metering rod and probably not accelerator pump related. It's more like something broke, it developed a vacuum leak, or some internal diaphragm ruptured.

Anyway, I threw in the towel and did a couple other things.

First up, I mounted that 4" ID tool storage tube in place of the 3" one that was on there up to this point

Flyin6 · « **Reply #501 on:** August 03, 2016, 09:28:09 AM »

Knowing that I will be stuffing things way down deep inside, I placed a "Yank" strap in the tube first so that I would be able to pull the deep contents out

Flyin6 · « **Reply #502 on:** August 03, 2016, 09:29:23 AM »

Because The first thing going into that cavernous hole is a spare tube for the back tire

Flyin6 · « **Reply #503 on:** August 03, 2016, 09:30:27 AM »

Followed by the tool kit, which is changing weekly as I add to or replace things

Flyin6 · « **Reply #504 on:** August 03, 2016, 09:32:00 AM »

It fit in there just about right...But I wish I had made it just 1" deeper...Guess I'll make another one!

The yank strap secures onto Velcro top and bottom

Flyin6 · « **Reply #505 on:** August 03, 2016, 09:33:52 AM »

Not wanting to stop there. I tried to cram the spark plug, rubber patches, and the spare bolt box in there, but the bolt box wouldn't fit!

Flyin6 · « **Reply #506 on:** August 03, 2016, 09:34:33 AM »

But everything else did!

BobbyB · « **Reply #507 on:** August 03, 2016, 09:46:21 AM »

Quote from: Flyin6 on August 03, 2016, 09:33:52 AM

Not wanting to stop there. I tried to cram the spark plug, rubber patches, and the spare bolt box in there, but the bolt box wouldn't fit!

Ziploc bag, if worried about bag tearing open; lay bag flat on table (before putting bolts inside) apply 100MPH tape to outsides of bag on both sides. Watch your worries disappear, much like the bolt bag inside the tool tube.

Flyin6 · « **Reply #508 on:** August 03, 2016, 09:46:43 AM »

Finally, I added a quick connection for a trickle charger which will be hooked to a solar cell

Flyin6 · « **Reply #509 on:** August 03, 2016, 09:47:24 AM »

Quote from: BobbyB on August 03, 2016, 09:46:21 AM

Quote from: Flyin6 on August 03, 2016, 09:33:52 AM
Not wanting to stop there. I tried to cram the spark plug, rubber patches, and the spare bolt box in there, but the bolt box wouldn't fit!

Ziploc bag, if worried about bag tearing open; lay bag flat on table (before putting bolts inside) apply 100MPH tape to outsides of bag on both sides. Watch your worries disappear, much like the bolt bag inside the tool tube.

That's a good idea young man!

KensAuto · « **Reply #510 on:** August 03, 2016, 10:12:01 AM »

Maybe the gas was just old enough to mess with something..
Could be the intake valve(s) are a little tight.....gummy tight or adjustment tight. I'd take 5 minutes and run the valves. I think you're supposed to do that after break in anyway.

moto123 · « **Reply #511 on:** August 03, 2016, 10:45:26 AM »

The accelerator pump is basically a rubber diaphragm. I have had similar idling issues when it dried up and cracked. I chased jetting for days until finding that the crack in the rubber pump. Might be worth a look. Either that or your idle circuit got plugged with dirt.

JR · « **Reply #512 on:** August 03, 2016, 11:14:55 AM »

I was thinking old gas too, something gummed up.

If you need a little more room, do you really need a dedicated chain cleaner brush in there? Maybe a good brush for many uses and a small can of spray cleaner?

Flyin6 · « **Reply #513 on:** August 03, 2016, 01:15:58 PM »

Quote from: KensAuto on August 03, 2016, 10:12:01 AM

Maybe the gas was just old enough to mess with something..
Could be the intake valve(s) are a little tight.....gummy tight or adjustment tight. I'd take 5 minutes and run the valves. I think you're supposed to do that after break in anyway.

Its been serviced once, but going after valve adjustment might be something I'll look into. But again this happened all at once...Although it did have some older gas in the tank

KensAuto · « **Reply #514 on:** August 03, 2016, 01:59:36 PM »

If a rocker is loose, then you'll know if it has a sticky valve. Maybe throw some seafoam in the tank and let it idle for a few? I use the heck out of that stuff out here where gas will varnish in 3 months of heat..

JR · « **Reply #515 on:** August 03, 2016, 02:20:37 PM »

I love seafoam,,,,,,,,,,,,

stlaser · « **Reply #516 on:** August 03, 2016, 02:34:18 PM »

Quote from: Flyin6 on August 03, 2016, 09:46:43 AM

Finally, I added a quick connection for a trickle charger which will be hooked to a solar cell

I need to do this for the WR450..........

Flyin6 · « **Reply #517 on:** August 03, 2016, 10:04:38 PM »

While over at the two wheel dealership, I was checking out the new Kawasaki KLR-650 in the blown up digi-camo pattern. Thing has a good look, but no power, a bad front suspension, a poor rear suspension and is loved by nearly as many who ride the steam powered DR-650 like mine

JR · « **Reply #518 on:** August 04, 2016, 12:33:28 AM »

Looks like a 007 bike with all stuff hanging in the back. I do like the camo if they would address the power.

TexasRedNeck · « **Reply #519 on:** August 04, 2016, 12:38:22 AM »

Don, the guy who helped me with my powder coating is an off road adventure biker. 1100 cc KTM.

TexasRedNeck · « **Reply #520 on:** August 04, 2016, 12:39:00 AM »

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JR · « **Reply #521 on:** August 04, 2016, 12:42:24 AM »

Don, your gel seat is calling you,,,,,,,,,,,,

Flyin6 · « **Reply #522 on:** August 04, 2016, 09:14:26 AM »

Quote from: JR on August 04, 2016, 12:33:28 AM

Looks like a 007 bike with all stuff hanging in the back. I do like the camo if they would address the power.

That engine is essentially unchanged from 1987, so I doubt we will ever see any big engineering changes. It's like the DR650. Just an old tug boat that has achieved small block Chevy popularity and a huge aftermarket

Flyin6 · « **Reply #523 on:** August 04, 2016, 09:15:23 AM »

Quote from: TexasRedNeck on August 04, 2016, 12:39:00 AM

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500 miles a day is tough

1500: Insane

TexasRedNeck · « **Reply #524 on:** August 04, 2016, 09:34:46 AM »

I just did the math on that. 62mph for 24 hours. Seems tough to imagine

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BobbyB · « **Reply #525 on:** August 04, 2016, 09:51:06 AM »

Quote from: Flyin6 on August 03, 2016, 10:04:38 PM

While over at the two wheel dealership, I was checking out the new Kawasaki KLR-650 in the blown up digi-camo pattern. Thing has a good look, but no power, a bad front suspension, a poor rear suspension and is loved by nearly as many who ride the steam powered DR-650 like mine

Minus the camo job, it's not a bad looking bike.

Flyin6 · « **Reply #526 on:** August 04, 2016, 10:22:37 AM »

Quote from: BobbyB on August 04, 2016, 09:51:06 AM

Quote from: Flyin6 on August 03, 2016, 10:04:38 PM
While over at the two wheel dealership, I was checking out the new Kawasaki KLR-650 in the blown up digi-camo pattern. Thing has a good look, but no power, a bad front suspension, a poor rear suspension and is loved by nearly as many who ride the steam powered DR-650 like mine

I like the camo scheme, but it comes in either black or Kawa green depending on the year. I'd say Black is the most common color for it.

The thing that makes that bike interesting is that it is water cooled. Water cooled engines can make about 50% more power than air cooled siblings. Example is the Water cooled Suzuki DRZ-400 vs my Air Cooled DR-650. The 400 cc bike, although being 250cc smaller, is a bunch more powerful than the bigger DR.

But, sadly, with the Kawasaki, the engineers decided not to put any power into their bike. It is a sled. Add to that it is way heavy. It approaches the weight of my big Triumph Tiger 800 with its water cooled three cyl engine.

So the combination of heavy and under-powered is not great in my view. That's why I went with the DR-650 with it's lightweight, air cooled simplicity

Minus the camo job, it's not a bad looking bike.

Flyin6 · « **Reply #527 on:** August 04, 2016, 06:47:15 PM »

I still don't have this thing fixed!

Cleaned it with sea foam and other sprays today and it still kicks back through the carb and backfires loudly on decel from revving it!

GRRRRRRRRRRR!!!!!

KensAuto · « **Reply #528 on:** August 04, 2016, 07:44:31 PM »

Did you check the valves? Wait, let me answer. NO you didn't!

stlaser · « **Reply #529 on:** August 04, 2016, 07:51:33 PM »

Rofl, H lover just handed the pilot his rear......

cudakidd53 · « **Reply #530 on:** August 04, 2016, 07:55:51 PM »

What about accelerator pump (diaphragm) tear like someone mentioned previously?

Flyin6 · « **Reply #531 on:** August 04, 2016, 08:14:22 PM »

I think it's the pilot jet clogged by bad gas

Watched a vid of a bike doing the same exact thing

Or a vacuum leak that just started up

TexasRedNeck · « **Reply #532 on:** August 04, 2016, 09:18:30 PM »

oooh oooh oooh, let me Don, let me!

Ken....your fired....

Flyin6 · « **Reply #533 on:** August 04, 2016, 11:12:23 PM »

Flyin6 · « **Reply #534 on:** August 05, 2016, 07:57:16 PM »

I am really be-fuzzled by this thing.

I did a lot of other stuff today, but I wanted to get this bike buttoned up and out of the way. I really wanted to get some things done on SquareD

So I checked the jetting, well some of the jetting, inspected for and I think I found some vacuum leaks (More than one) but very small ones. Apparently the rubber collar which clamps onto the carb barrel is notorious for leaking. Spraying carb cleaner around the flange produced a momentary increase in "Idle/stumble" speed.

So I addressed all that and the darned thing is still doing the exact same thing!

My carb has a nice access plug in the fuel bowl which one can pull to gain access to the pilot jet.

It's here:

Flyin6 · « **Reply #535 on:** August 05, 2016, 07:58:15 PM »

Now, remember this carb is not all that old but look at this weird looking green stuff coating the inside surface:

Flyin6 · « **Reply #536 on:** August 05, 2016, 08:01:11 PM »

Yea...And that with the fuel filter that was installed!

Once removed, you have access to the main pilot jet and the metering valve barrel, which I removed and disassembled. It also had that strange green film all over it.

It did not clean up easily, like it was anodized on there or something. And I also had sea foam soaking in that fuel bowl for 24 hours

Flyin6 · « **Reply #537 on:** August 05, 2016, 08:02:54 PM »

I sprayed a bunch of carb cleaner up inside that hole and then removed the air metering valve and cleaned it and sprayed out the passages

Flyin6 · « **Reply #538 on:** August 05, 2016, 08:04:03 PM »

Then the idle fuel metering screw

Flyin6 · « **Reply #539 on:** August 05, 2016, 08:05:04 PM »

Next, I installed premium Parker hose and another new fuel filter

Flyin6 · « **Reply #540 on:** August 05, 2016, 08:07:43 PM »

Thinking I was done with the carb problem, while I had the tank off, I wanted to place some more padding into the areas under the fuel tank. I can see it moving about a little while riding aggressively. These two rubber discs hold the front of the tank, while two bolts secure it in the rear. I'll be doing something about this

Flyin6 · « **Reply #541 on:** August 05, 2016, 08:09:40 PM »

So, using foam stripping designed to fit between the truck bed and a topper, I built up several areas

Flyin6 · « **Reply #542 on:** August 05, 2016, 08:34:14 PM »

...And, as expected, the tank was very snug, with zero FAS (Flop About Syndrome) ;)

Flyin6 · « **Reply #543 on:** August 05, 2016, 08:40:26 PM »

And this is the point where I filled the carb and fired it up expecting all to be good in my steam engine, but it was not to be.

Ba-wosh it said and the engine stalled, and I knew right away that I had a bunch of well sealed clean parts acting in exactly the same manner as before.

This has me scratching my head and wondering if some ignition module suffered a partial failure or someone cast a spell on it or something!

But, I went on to remove the unnecessary kick stand safety switch. For a fast getaway bike, wait-a-minute switches are not desirable. So I made it go away.

Here's the little sucker:

Flyin6 · « **Reply #544 on:** August 05, 2016, 08:43:06 PM »

I wired around it and removed the unnecessary parts

Flyin6 · « **Reply #545 on:** August 05, 2016, 08:44:24 PM »

It's all cleaned up, and I even gained a hard point which I just may use for something down the road

Flyin6 · « **Reply #546 on:** August 05, 2016, 08:44:59 PM »

So, here I sit, still not finished!!!!!!!!!

stlaser · « **Reply #547 on:** August 05, 2016, 10:30:59 PM »

Just want to point out the obvious. The sea is green & you were using "sea" foam...... ???

JR · « **Reply #548 on:** August 05, 2016, 10:37:21 PM »

I do wonder what the green is. Whats in your gas?

Sammconn · « **Reply #549 on:** August 05, 2016, 10:48:59 PM »

To me it looks like sea foamed varnish.

Chief, how old was the gas? Regular or premium?
I ask due to the ethanol fiasco, and the havoc it causes with rubber bits.

It looks to me like varnish build up, which with today's gas happens fast.
The green from the sea foam.

Now what is causing the backfiring and not running well, still rests inside that carb I think.