Master Mechanic Gave Up On This 650cc Street Legal Dirt Bike
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- Опубліковано 8 вер 2024
- I buy a 1995 Suzuki DR650 street legal dirt bike and attempt to fix it. #Suzuki, #650cc,
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THIS WAS MY BIKE FROM 2014 to 2019! IT WAS AWESOME!! I wish I kept it. So much quality time in Death Valley on this machine!
A bush pig!! I have one and still ride it weekly. It has been round Australia about 3 times. Legendary bike. I agree. The carb
I want one so bad, just checked the 2023 model brand new around 7000 euros,
I would check for exhaust restriction and also do a careful inspection of the intake manifold. It is after all 28 year old rubber. Good luck
I was thinking the same thing.
I came here to say this
That's the same thing I was thinking
That’s exactly what I thought also. I never saw anything smoke wise come out of tail pipe
GREAT VIDEO, THANK YOU
AM THINKING SAME, I HAD A KTM 620 RCX THAT BEHAVED SIMILARLY..... THE MUFFLER INTERNALS HAD COLLAPSED MOSTLY PLUGGING FLOW
I like it when you include the adventure of going to look at and bringing the machine home added to your video Anyone else?
You get what you get so quit complaining.
@Jake Demuss it's called complaining lol no matter how ya want to put it.
I had a Raptor 660 that acted like this. I chased the issue for a long time. It turned out to be a sheared woodruff key on the flywheel. Timing was mechanically spot on but the flywheel had rotated and so it was firing when the intake valves were open, which could explain the smoke coming out the intake. The other thing, these vacuum slide carbs are a real pain. Very sensitive to air/fuel mix. With the lack of adjustment on the needle you have to play around with the mixture. It could be that its dumping way too much fuel when you roll on the throttle.
I definitely think it’s a timing issue being it’s blowing out of the air box
This is good thinking. Especially with a high compression engine like this the wood drift key in the fly wheel could break for any given reason.
@@joshualynn6994 Too lean will do that too
It’s spark wastage .look at boot on plug .when checking for spark ,it’s leaking spark .
The air filter will be the issue! I had the exact same issue, you need the filter in place for the slide to be able to move up and down other wise when you throttle it won't have enough vacuum/pull to move the slide👌🏼
Mine runs just fine with no air filter hasn't had one for 2 years.
@@jerrywilcox9890 that's not good lol
It doesn't matter whether you have an air filter on it or not
The same amount of air comes through whether it's on or off the difference being whether the air box lid is on or off but the slide will still move the same
@@MrATOMBOMB420 a filter is to an engine as a resistor is on electronics, is it not? Seems so, common sense wise
I have 2 of these bikes. One to ride and one for parts. This vintage (1991-1995) DR650 share almost no parts with the 1996 to present models. The BTS carb is known to be problematic, especially off idle. I ditched mine for a 40mm pumper carb. It flows and responds much better at low engine speeds.
So would you say 96 and on are better overall?
@@M.TTT. not at all. Just pointing out, other than the name, the two models share nothing in common.
Joe, I have to say thanks for your videos. I came across a portable generator that a guy wanted to trash it. No spark.
I took it home , no spark. I remembered the video when you pulled the plug boot off and found no wire. You cut it back to good wire, reinstalled the boot and got spark. Same with this generator. 4 pulls and it runs . Thanks Joe.
Awesome!
I should've never sold mine. So easy to work on. This bike helped me learn how to work on all my bikes. When you saw the carb was broken, I remembered how it was the only junky part on my dr. Great video
You might want to take a look at the cam journal on the cylinder head again. It sure looked like the cam had ate into it quite a bit. It would explain the super loose rocker arms/valve adjustment
Yep. Good eye, there.
saw the same
That is just to funny, I picked up a 1992 DR650 yesterday. 👍
I have the 93 with only kickstart, killer bike, just love IT.
You need to tighted the balancier chain on it, put a 150 main jet and it will be a wheelie machine
Doublecheck the intake manifold for cracks. Hard to see when on the bike. Keep up the great videos!
spray starting fluid on manifold, increased rpms will reveal
Hi, I noticed that when you first checked for spark, besides the spark at the electrode, you were leaking a massive amount of spark from around the top of the boot to the head fins. May be a factor as spark voltage increases as you Rev on some systems, causing a worse shorting problem as voltage increases.
I saw the exact same thing
Saw it too!
Well off course it’s gonna cause it headaches and yes spark increases with spread ,more fuel more sparks .think spm
Most people love em or hate em , pos oem carb , and constant need of valve adjustment.. but once it's cranked it'll literally fly.. good luck 👍
Check for blockage in the exhaust.
kina what im thinking.
I was noticing to that no smoke out of the exhaust even though he put oil in the cylinder.
I agree
Looks like the end of the cam has alot of shavings under it, looks like it might have been run low on oil. As for as it reving up i would put a good battery on it.
Did anyone else notice the metal shavings around the cam journal when he was checking the timing ? That looks chewed up real bad !
looks like the camshaft "bearing" on the chain side is totally gone! The cams seem to be worn out as well. I know such problems from the DR 750/800. They need 1350 +- 150 idle speed. If they run too long too low on the sidestand, the whole cylinderhead-/rockerboxassambly is gone due poor/no oil supply.
@@besenwieslersepp1011 It definitely has a strong bottom end but it's gonna need a new cylinder head for sure.
@@Michael-to7oz sadly the cylinderhead and the rockerbox have to be changed together as a unit. Because they are bored and reamed together.
And I must say that dog is fast as shit too lol. U could see how quick he is in the video u were riding the yfz in ur backyard after u got it done.
I owned a 02 DR 650 dual for 6months and it had to go, unless you gear them different or do sprockets they are slow turds and with a full tank of gas they are really top heavy on the trail, good luck
Heat gun on carb intake boot softs the rubber up easier to get out
Check your tail pipe. Lots of smoke out the carb, not a puff out the pipe. Sat outside for a while. Could have nest, trash, etc clogging it up. 🤷🏼♂️
Check the wiring harness by the light support bracket on the right side of the steering head. The metal can be sharp and cut the wire insulation.
I will check that
Noticed little or no smoke from exhaust it could be it's blocked rodents nest and choking engine hence carb smoking
Start it with exhaust off see it runs
Exhaust is the most probable cause. That’s why it was smoking back through the carb. Exhaust can’t expel the air quick enough when you try to rev the bike
After the Vinnie dance, I was like ok, now I see why Vinnie doesn't like him 🤣🤣✌
Cam bearing looks knackered, on the side you were showing the timing marks.
☝☝☝This !!! ☝☝☝
When you were checking for a spark earlier the spark was shorting out from the rubber that surrounds plug onto cylinder head so you had two sparks, you missed that.
I saw that to
Finally you’re working on my bike 😂
I have an 04. On mine the fuel/air screw has a washer and a small O ring on top of the spring. When I bought it, it was missing and ran like crap. Once I sorted that it runs like a top.
yes I did noticed that also, it is missing. I think the o-ring is crucial.
I had the same thought. Should be an O ring to seal the screw
Often the little o-ring gets stuck inside the carburator - check for that first..😉
cdi box or the pick up is failing
Common on old big thumpers
Hondas do it all the time
Seeing that puff out air box says a lot
Looks like it has a after market fuel tank, acerbis fuel tank cost almost as much as you paid for the bike 👍 You got a great deal there's so many after market parts for those bike , 👍
35min in Joe, that top end is history dude....drive side cam journal torn up as is the ally bearing surface (likely the valve cover too). Take a close look at the rocker pads for wear marks too. You're gonna need to dig into this one :(
Just a word of caution: Pre-1996 DR650's are VERY different bikes than post-1996 DR's. Pre-96' bikes are very difficult to source parts for, there is not nearly as much aftermarket support for them.
Check the chain-driven balancing system religiously, as it will grenade the motor. I believe the factory service says every ~2000 miles or so it should be checked/adjusted. Also, the bike may not run without an air filter. The carb actually needs the filter in to run properly.
The biggest thing with the earlier DR's is that parts are difficult to source. They are great bikes, but just simply no where near as good as the 96' and later models, and often leave the owners getting rid of them for cheap because parts are nearly impossible to source.
You got that for a steal!!! When I sold mine I got 2500 cash out of it, had a set of Baja lights on it to. Should have kept it!! Enjoy bud!!!
You need to take that bike for the Idaho Backcountry Discovery Route. It's an adventure ride :)
I am surprised Joe has not been invited to one of those weekend gigs, Polaris Ranger at Black Bear Pass, or Can-Am RZR in Moab UT
I would upgrade the carb to a flatslide carb. Mikuni TM40 or an FCR. That'll wake it up lol.
I rode an xt 600 from San Diego to North Dakota. Iron ass.
Indeed! Much respect, my friend!
🔥remove that muffler/silencer I’ve seen them plug up over years of ppl putting around. Fire it up with just header🔥👊🔥🔨🏍⚙️
Check the exhaust a engine can only take in as much air as it can blow out. If the pipe is blocked (critters) it could easily blow back through the carb.
When you had the cam cover off to check timing, the cam journal looked cooked.
Love the DRs. Had a 92, rode the hell out of it even a trip from Southern California to southwest Colorado. Ass was sore but that bike is fun, tons of power, smooth as silk, super fast. Will bite you if you aren't ready for it.
was thinking the whole time it needs the filter. glad to see you with a dr650. i been riding dual sports for many years and have had many different models. the dr650 is bout the best one made. good score for $800.
I would double check to see if it’s the right cdi and check the pickup.
An old friend had a Suzuki DR 350. The previous owner had taken it to several dealerships and other mechanics and couldn’t get it to run correctly. My friend spent hours and hours and put quite a bit of money into that bike but it never ran right. We all conspired to burn it in the desert and then surprise him with a comparable bike that would actually run😄
I’m going through the same thing with my Mojave. I’ve replaced all the electronics even though I knew they were good. But I’m starting to believe that it maybe an issue in the case. Runs good. Starts up. But very same issue. Starts right up. But u can’t press the gas. It has to run for like 15 mins before u can be able to ride. But when your riding it rough and let off the gas it dies. But first kick turns right back on. Idk 🤷♂️
I did not see one puff of smoke out of the exhaust!
Maybe plugged ?
I've owned two Suzuki DR650s. Very familiar with them. Aftermarket tank, no front turn signals, that seat sure is ugly. Oil level is VERY low, I wouldn't run it like that. Oil level should be at the top of the sight glass when the bike is vertical. I bypassed the clutch and kickstand nanny switches on mine. Just something else to fail in the middle of nowhere. I ALWAYS clean really good around spark plugs, valve covers, oil fillers, oil filter covers, etc. before removing them to keep dirt out of the engine. You don't need to see the timing marks, just turn the crankshaft till all the valves are closed. There will be play in the rocker arms. They will stay closed during the entire compression and power stroke, so you have a lot of room tom play with. The DR650 uses 4 valves, operated by forked rocker arms, which is somewhat of a pain. I don't know why it needs more than 2 valves. While there are two plugs, it will run on just one, and only actually needs one, but in the center of the head. Don't know why Suzuki made it overcomplicated. It's not a high power engine. The carb can be converted to a single cable. Works a lot better that way, and the cable is less likely to bind. There should be an emulsion tube right above the main jet that will come out when you remove the needle. Sometimes called a needle jet. I did not see it. Maybe it's missing. Parts diagram shows it has one.
The broken tube is the choke-tube. With uncorrect flow in that tube and without aircleaner, it can be difficult to start the engine at low temp. I also missed the o-ring and the tiny washer on the idle-mixture screw (may be you dont f.ilm the "extraction").
If it runs, look at the manual for the correct idle-speed. Those singles are notorious for killing their camshafts and rockers at too low idle-speed on the sidestand due to poor oil supply in the cylinder head.
Besen.... is this true of the models after 2016? I do not think so? What do you think? There are tens of thousands with well over 40,000 miles and no problems.
@@davidfalgout7304 I have a 1997 DR 800. It runs perfect with 70.000 km on the clock.
But if I let it run for 5 minutes on the side stand with the idle gas too low, the cylinder head would be scrap. There is a reason why the manual says: 1350 rpm +- 150.
I have n idea of the newer Models.
@@besenwieslersepp1011 I would think that a 20+ year difference in engine design would mean the 2016 and later 650 engine would not suffer from that..... what do you think?
@@davidfalgout7304 I can't judge that, but it is to be expected that improvements will have been made in 20 years.
Those side panels & front light are just begging for decals once they are cleaned up! Definitely a nice grab!
I agree 👍
Good u got the 650 electric start. My son has the 350 kick start only and it's a pain to start. If you know the exact procedure to start them he says it not hard but if you don't takes too many kicks to start. He does love it because it's an on/off road.
There is a way to get into those analog odometers. I had an old 91 gmc that I replaced the gauge cluster and the odometer was analog and I was able to turn it back and set it to the actual miles the truck had
Made the same assumptions as you did on a xr250 in Thailand. Spent about 3 weeks working on it. As a mechanic I failed to use the KISS meathod and wasted time and money. Go back to the original problem, CDI. I was sold a wrong CDI several times. Finally went to a running bike and took the CDI unit. Simple fix. The wrong CDI units started the bike just fine and had a stong spark but would not accelerate. This lead me down the same path you took. I assumed because it started so good it must not be the CDI unit. I did everything you did also just to have it do the same thing every time. Hope this helps. Love your channel.
That gas tank in huge.
Should try and get your hands on Drz 400
If the new carb doesn’t fix it. I’d check the woodruff key in the flywheel.
For this reason, Always take the extra time to remove your carb properly even if it means to remove your airbox. Now you have a broken carb and possible a crack in your intake boot. 😢 10 extra min.
maybe you could test using something to restrain fuel flow in that line...vise-grips or an old fuel petcock might do the trick...before ordering a new carb...good job mate i really enjoy watching you working !
Battery voltage was low - should be over 13V when charging. 12.8 is nominal (fully charged) voltage. Charge needs to be higher. Most standard OEM ignition systems do not work well with low input voltage. Plug spark looked really weak so maybe cannot work with more fuel/air. Your replacement tube should be OK as still restricted at 1 end. But replace carb with non vacuum item - much more reliable long term.
Hard to tell what it really sounds like from the video and didn't see anything shoot out of the muffler but maybe try disconnecting the muffler and run just the header pipe to see if it's clogged. With you saying it sat outside, something my have gotten in it to clog it and could be the reason it won't rev out, might not be able to breathe.
Air filter is a must. MANY times its the lack of a air filter.
I don't know close to what you know...the only thing I would have tried in this situation would be shorten the makeshift line you replaced the broken tube with...might be too long of a distance to travel with the increased diameter of the hose...and maybe increase the idle screw a bit, other than that I'm stumped. Good job on all you do bud!
Just the acerbis 25 litre fuel tank by itself cost around 400 euros !
You need to find a xr650l next. Those are a beast of a bike.
He only buys non running bikes. All the honda Xr650Ls still run great. LOL
@@GratefulEd907Honda owners are like Stepford wives.
@@bananabrooks3836 I’ve seen that movie and honestly think the Stepford wives were way better than an actual wife. So thank you
@@GratefulEd907 😁😁Haha, good defence.
Hi, if it helps, I have a 93 model DR 650 R with kickstarter, it's a wonderful bike. If you have to change the carburetor I recommend the Mikuni CVK40 that will probably solve the problems that appear in the video.
I have a 1991 dr350.broken tube on carb like you.switched to a new pumper carb.bike runs perfect now.thanks for the great videos.
Back pressure in the blocked exhaust pipe ?? One thing you haven't checked for is a mouse nest in it
Love the channel, always a learning moment, good looking bike. I owned a 96 RF650 and thought it was a great bike
Check the CDI coil. Measure the resistance of this coil. The values should be listed in the manual. Greetings from Poland
That compression reading is good! Still like new, it's gonna scream.blowing back through carb by the intake valves. The valves on them are kind of a pain to set especially the exhaust.
Jaysus. That's a FUBAR'd cam journal in the head at 34:46. Look at the aluminum that's galled up and spilling out the side. I doubt that head will live much longer without wiping out the cam with it. when it seizes up. Find out what's causing that! Lack of oil pressure to the cam? Debris in oil passage? Or low oil level and run dry by the PO maybe.
It's the air filter. I've never had a cv carb work properly without one
The dancing was a riot
You need to actually hook up a battery to the terminals for the CDI box to maintain power for it to the coils it’s a safety mechanism as soon as you touch the throttle it will die complete the circuit with an actual battery then put jumpers on
I know you had multiple plugs in it but I'd recheck the plug wire and cap. It was arcing between the head and cap when you were checking spark. Not sure if that's the whole problem but could definitely be part of it. Good luck from a fellow 'sconsinite!
I saw that too.
Nice bike joe yeah got to be a carb problem and possibly filter don’t really know much about these bikes but you will figure it out for sure vinny thought it was crap lol💩💩💩👍👌🔧🔧🔧
Excellent dismount unloading the bike. I bet @MichaelSabo couldn't do that! 🤣🤣
Bulletproof bikes. Have 95' myself. Love the bike!
Well, they can't be that bulletproof if Joe has one in his garage.
Hi Joe love the content, when you were doing your spark test on the big DR it looked like there was spark jumping fro the plug cap (boot) to the head, possibly cracked spark plug cap. Hope the helps. Keep up the good work.
i saw that too but it was a spider silk when the bike was cranking the plug was moving and light was shining on the silk making it look like a spark.
I had a dr 350 that worked like this ..once my kid noticed a spark coming from the spark plug boot to the head ..change tje boot and the problem was solved. I also saw the fugitive spark when the first sparkplug was tested
The first bike I put any amount of miles on was an early 90's DR650. When you said you were going to take the carb off I was thinking, "Good luck with that buddy". Seeing you struggle with getting it out brought back memories for sure. You have to take out the battery and air box and it is still a really tight squeeze to get the carb in and out. That said, the DR is a great bike.
I also had that Acerbis tank on my bike and it leaked where the front mounts attach to the frame. The plastic had spider web cracks and the gas would find its way through the cracks. I tried many different things to patch it but it is hard to find something that will bond to plastic that will also not get broken down by the gas. It was a chronic problem that I never solved. I eventually sold the bike and got a BMW.
i woukd make sure the exhaust pipe is clear if it pops back through the carb idleing,,,,, great channel bloke👍
Really fun bikes these Joe nice pick up bud if it isn't the carb & the air filter only thing I could think of is exhaust definitely worth a look after you get the carb & airfilter the bike is in really nice condition once running you should have a load of fun really nice machines to ride have a nice week mate look forward to you getting it running great content #2Vintage 👊💨
Hey Joe I think the guy from low-buck garage has one of those bike as well not sure if it's a 650 or not but it sure does look identical. I forgot he had some issues with his as well but for 800 bucks that's a good deal. That is definitely one hell of an Enduro.
I love when Vinny gives his expert opinion on your new bike purchases, I'm thinking you should probably start another UA-cam channel and call it the adventures of Vinny it would surely be a smashing hit ! Love the VIN !!!
Put a camera on his collar
Vinnie's collar cam lol
If a Master Mechanic touched this bike, YOU wouldn't have to turn a wrench on it.
Comical title.
I had the same problem with my DR650 ordered a DYNOJET KIT for the carb fixed the problem instantly
It is the carb I've been a suzuki guy all my life these DRS have carb issues .great video your awesome!!
Lean on idle jet, need to richen to compensate for ethanol in fuel. Possibly low low level in float bowl too. Dont need new carb - fault diagnose what you have for cheap. Can add bigger main jet and raise needle once richened on pilot system first. Thoe plug caps go hi resistance too, but you have a good spark at the moment. Good luck!
Maybe there is a restriction on the exhaust. Check out the pipe and muffler.
Well if a Master mechanic couldn't figure that bike out you got to be the king of all mechanics! 👍👍
I bet there's 10 of us saying why no exhaust smoke at all
Vinnie is eating the yellow snow! 😂
I think the fuel tank looks goofy 🤪. Maybe the CDI is causing errant sparks due to the dual plug setup. 🤷♂️ Something tells me that you'll figure it out.
Love the channel, ARGH - hate carb problems. Nice bike, quick turnaround? Joe tested, 🐕Vinny approved
Check for plugged muffler.
Maybe try pulling the baffle out of the exhaust?
I ride DR 650 DJEBEL, red & white (1991) 4 years, no problem ever, torque monster, 48 hp, awesome bike with kick start.
I would just get an air filter and try that first, as they say just do one thing at a time to learn exactly what the problem is, good luck Joe.
I have a 91 dr650. The carbs on these bikes are not easy to tune. They tend to run too lean. It’s gonna run lean with no air filter.
Start there then consider the valves (yes I know it has good compression)
I'm guessing air filter first. Next possibly the air boot to carb or to head is cracked and check with starting fluid for leaks but still think air filter. Sold my DR350 a reliable beast but flying ants had gotten into the carb bowl and carb would plug up intermittently until I pulled it and go those out. Bulletproof bike.
I would try soldering the little brass tube back on... and fail for sure... :)
sounds like its ready for a starter clutch. may also need a good battery to run right, some machines wont run with just a jumper pack
Hi there, Kevin from Australia here. I really enjoy your show, what you do and your presentation is real and honest. And the way you talk to yourself at times hehe, and how you deal with disappointment. I have to ask where do you live, because sometimes i open your show and there is literally feet of snow outside, and to me that is always a shock lol