Nicely done no bullshit no making coffee no patting your dog no crazy edits just straight up fix it there is quite a bit of work there and you made look easy and no stress cheers
All time best vid I’ve ever watched on any rebuild. It’ll come in really handy for me because my brother just bought a ‘19 and everything he owns he blows up.
Another great video. I like the fact that you don't have endless footage of pointless crap but just show the relevant stuff. Attention to detail is really good as is your narration. It's been interesting to see inside the heart of my beast. Thank you and subbed.
Thank you so much for this video, my DR has been down for years for me to get the time to tear it down to replace the motor cases, you just answered a lot of questions for me. (oh yeah, just subbed.)
Wow, this is a reference video. It's super interesting. I learn a lot from this video. You are really clever at putting all this together. Well done. Thank you so much.
Thank you for taking the time to make this video, very well done I have tried to record some of my repairs and they are not ready for public viewing it is a lot harder than you make it look, Lol, you have saved a very nice DR. ; )
Yea there is 10x more footage that was not shown lol. It is not easy getting all the angles and clips but worth it since there really aren’t many good dr650 rebuild videos. Thanks for watching.
Freezing bearings makes it far easier to get them out of cases. For outer bearings on shaft warming bearings and cold shaft will help. Steering head bearing fitting is easier if you freeze bearing first in freezer. Heating up engine cases in oven helps when assembly. Its common sense. Lighter gas will freeze stuff too but dont smoke or have flame or heat around and open door and window so it doesnt explode! 😂
Thanks for your video. I am using your video to reassemble the top of the engine because I had a leak at the base of the cylinder. - Can I use copper grease for the 4 cylinder tightening bolts? - Do you recommend using the original Suzuki gasket kit? Thank you
La verdad que anque hablado en inglés lo disfruté...me parece un hermoso motor, sencillo, sólido, de la vieja escuela, de esos que se contruían para durar toda la vida... Si algún día tuviera el capital y la oportunidad me haría de una DR650...
I'm on my 3rd DR50 motor rebuild and the top of the stock piston was in rough shape so I decided to go with a JE 10.5:1 piston but it feels pretty tight in the cylinder. Stock will slide in and fall all the way down un-assisted but the JE stops about 2-3 inches in. It will go all the way down with a little pressure but worried it will seize once it expands under operation temps. I made sure the piston was oriented correctly before checking. Do you recall anything similar? Thanks!
Yamabond RTV... All manufacturer's have their own oil & fuel resistant RTV sealer they use. I personally use Ford's grey diesel recommended RTV (as that's what I have access to) for years with no issues ever on dozens of rebuilds. Red Permatex should work fine as well, I forget what the color/uses are, but if I remember correctly, red is one of the more oil resistant.
Thanks for this video! Great notes giving during the assembly as well...I've got 50k on my DR650...always been super dilligent about oil level and changes (synthetic always) how long do you think I'll be able to go before I need a rebuild. engine sounds clean and never smokes or burns oil.
There is really no way to tell without opening it up and inspecting. If you don’t know much about motorcycles I would just keep up with the maintenance and wait until something goes wrong.
Awesome, thanks! Can't wait to start putting mine back together. Is the thrust washer that goes under the clutch basket sleeve bushing about 1/8" thick? I got this spare motor (in pieces) with the DR I purchased so I didn't see it come apart. Also, aside from the weight is there a reason you didn't fully build motor before installing it into the frame?
Yea the thrust washer is pretty thick so that’s the one. I had a pretty hard time getting the bottom end out so I figured I would just put it back in before I put the top end on. Good luck getting yours back together.
@@MarleyJaxGarage Thank you! That makes sense. Still waiting for a few parts but I'll see how the removal goes. Thanks! Looking forward to the next video. 37:35 stator (aka magneto) cover
Hello, on 7:39 you install the shaft bearing retainer. I haven't this part on my bike and i have oil leak. I did some research and i can't find this part on suzuki oem spare parts. Could you help me to find it ? Thanks
Where you got a new cylinder head bolt that has been broken? Did you buy a random one same size or made from exact specifications metals? Because as I think You still had to drill it and make another one, new thread for that bolt
What's the purpose of the plastic cap for the camshaft? why did they make a hole for a cap in the metal? also what direction should it go? it's not symmetric on its inner side.
I'm stumped! Just put the last bearing in and installed transmission, crank and balancer with dots in alignment. I operated the crank by hand via piston arm, felt some resistance and I'm getting a low whirring/buzzing noise. Sounds like it's between the balancer gear on the crankshaft and the case or bearing. Definitely didn't sound like that prior to teardown. Am I missing a washer or is the crank too close to the bearing or something? I didn't take crank or balancer apart. I'm afraid to close cases until that's solved. Thanks!
What kind of bearings did you put in? If you take the balancer out and turn the crank over does it still make that sound? If you turn the bearings by hand do they sound different? There are no washers there so I would just eliminate things until you find out exactly what it is. You could also take the crank back out and just install the balancer to see if turning that makes the noise. Make sure the bearing have some lube too, dry bearings definitely sound different.
@@MarleyJaxGarage All new C3s, all lubed, no funny sounds from them. Mostly Nachi, 2 Koyos, 1 NTN 63/22 which the balancer sits in. Sounds perfect without balancer. Is it possible it's just the gears meshing together and I'm overthinking it or should they be silent?
@@MarleyJaxGarage just figured it out. The balancer bearing wasn't fully seated. Left side was about 1/16" higher than right. Sounds much better now. Thank again!
@@MarleyJaxGarage Thanks man! Just finished mating cases. Your method of heating up the socket or puller as a "slug" worked great for popping crank in and putting cases together. Barely any muscle needed. 👍🏽
Hey, at 24:07 is that a fully metal head gasket or a fiber/metal combo? The kit I ordered has the combo head gasket but came with the OEM all metal base gasket. Thanks!
I am currently having trouble getting the sprocket and chain back on the camshaft. It is like someone stole a link from the chain when I wasn't looking. I took the clutch cover off to make sure that the chain wasn't kinked or anything but I just can't get the sprocket back on with the chain on it. Any idea what I am doing wrong?
@@kebabbra is it the correct chain? Maybe count the links and verify. Are any of the parts new? Only other thing I can think of is that the cylinder or the head is not seated all the way.
I’m in Maryland. Can’t believe you made it to 54k, that’s awesome. You must maintain it really well. I would say it’s getting close to needing a freshen up haha.
@@MarleyJaxGarage It's the best tool for transportation. So many adventures I wouldnt/couldn't have gone on with my car. Lanesplitting is legal here so traffic is non-existent for me... I don't do much for maintanence other than religiously change the oil every 1000 miles or so. It needs a valve adjustment bad!
3rd gear pinion can wear so its a good idea to check the condition and the gear selecter forks. Theres a 3rd gear mod by a gear engineering company thats far superior to suzuki part. Look on google.
There should be an o-ring behind the oil filter. I had to go back and put it in there once I saw I missed it editing the video.
How lucky that you filmed it all :D
Nicely done no bullshit no making coffee no patting your dog no crazy edits just straight up fix it there is quite a bit of work there and you made look easy and no stress cheers
Excellent video. Appreciate you taking the time to make this!
The best DR assembly video I’ve seen. Thanks!!
This video has been so valuable to me. Thanks for putting it together.
Nice craftmanship
Excellent video, very clear, nice camera angles. Thanks for posting this up!
Thanks for watching.
Thanks for taking the time to make this edit. Nice work!
Appreciate the comment. Thanks for watching.
Fantastic work man thanks.
Outstanding video! Thanks for putting that out there!
Loving this rebuild series so far, learned a ton of valuable information - thx
Thanks for watching and I appreciate the comments!
Yeah learned a lot too over here ✌️
Great video, thanks for posting it up.
Super vidéo, bravo !
Awesome video. Very informative and detailed. Thank you for posting and sharing
All time best vid I’ve ever watched on any rebuild. It’ll come in really handy for me because my brother just bought a ‘19 and everything he owns he blows up.
Another great video. I like the fact that you don't have endless footage of pointless crap but just show the relevant stuff. Attention to detail is really good as is your narration. It's been interesting to see inside the heart of my beast. Thank you and subbed.
Yea I try to cut it down enough to keep people interested. Thanks for watching and the sub.
Thank you so much for this video, my DR has been down for years for me to get the time to tear it down to replace the motor cases, you just answered a lot of questions for me. (oh yeah, just subbed.)
Wow, this is a reference video. It's super interesting. I learn a lot from this video. You are really clever at putting all this together. Well done. Thank you so much.
Thank you for taking the time to make this video, very well done I have tried to record some of my repairs and they are not ready for public viewing it is a lot harder than you make it look, Lol, you have saved a very nice DR. ; )
Yea there is 10x more footage that was not shown lol. It is not easy getting all the angles and clips but worth it since there really aren’t many good dr650 rebuild videos. Thanks for watching.
Thanks a lot for sharing!
Looking forward to hearing it run. Really interesting series. You are a damn good mechanic but you also show it isn't magic.
Hoping to get it running this weekend and hearing it run myself. Thanks for watching.
Very interestiing page ☺️☺️☺️
Clever you 😎
Freezing bearings makes it far easier to get them out of cases. For outer bearings on shaft warming bearings and cold shaft will help. Steering head bearing fitting is easier if you freeze bearing first in freezer. Heating up engine cases in oven helps when assembly. Its common sense. Lighter gas will freeze stuff too but dont smoke or have flame or heat around and open door and window so it doesnt explode! 😂
Thank you
Thanks for watching!
Penny makes a great gear jammer.
New subscriptor.. Gracias!!👍👋🥂🎄🇦🇷🇪🇦🎆
Do I have to wait a bit before tightening the valve cover gasket. Thanks for your video. Alain
Thanks for your video. I am using your video to reassemble the top of the engine because I had a leak at the base of the cylinder.
- Can I use copper grease for the 4 cylinder tightening bolts?
- Do you recommend using the original Suzuki gasket kit?
Thank you
La verdad que anque hablado en inglés lo disfruté...me parece un hermoso motor, sencillo, sólido, de la vieja escuela, de esos que se contruían para durar toda la vida...
Si algún día tuviera el capital y la oportunidad me haría de una DR650...
I'm on my 3rd DR50 motor rebuild and the top of the stock piston was in rough shape so I decided to go with a JE 10.5:1 piston but it feels pretty tight in the cylinder.
Stock will slide in and fall all the way down un-assisted but the JE stops about 2-3 inches in. It will go all the way down with a little pressure but worried it will seize once it expands under operation temps. I made sure the piston was oriented correctly before checking. Do you recall anything similar? Thanks!
Lifesaver video - what did you use between the cases as a gasket? Thanks man!
Yamabond RTV... All manufacturer's have their own oil & fuel resistant RTV sealer they use. I personally use Ford's grey diesel recommended RTV (as that's what I have access to) for years with no issues ever on dozens of rebuilds. Red Permatex should work fine as well, I forget what the color/uses are, but if I remember correctly, red is one of the more oil resistant.
I’m going to need to do this. What engine stand is that, and would you recommend it or does it have some serious flaws?
Thanks for this video! Great notes giving during the assembly as well...I've got 50k on my DR650...always been super dilligent about oil level and changes (synthetic always) how long do you think I'll be able to go before I need a rebuild. engine sounds clean and never smokes or burns oil.
There is really no way to tell without opening it up and inspecting. If you don’t know much about motorcycles I would just keep up with the maintenance and wait until something goes wrong.
@@MarleyJaxGarage appreciate the reply.
hello, tell me what the compression should be in this motor?, thanks
You are saying you put the concave side out of the clutch hub washer but this looks like the convex side is out.
Awesome, thanks! Can't wait to start putting mine back together.
Is the thrust washer that goes under the clutch basket sleeve bushing about 1/8" thick? I got this spare motor (in pieces) with the DR I purchased so I didn't see it come apart.
Also, aside from the weight is there a reason you didn't fully build motor before installing it into the frame?
Yea the thrust washer is pretty thick so that’s the one. I had a pretty hard time getting the bottom end out so I figured I would just put it back in before I put the top end on. Good luck getting yours back together.
@@MarleyJaxGarage Thank you! That makes sense. Still waiting for a few parts but I'll see how the removal goes. Thanks! Looking forward to the next video.
37:35 stator (aka magneto) cover
Hello, on 7:39 you install the shaft bearing retainer. I haven't this part on my bike and i have oil leak. I did some research and i can't find this part on suzuki oem spare parts. Could you help me to find it ? Thanks
ciao sono italiano. mi puoi dire i valori del serraggio bulloni 🔩 testata per la chiave dinamometrica ? sono uguali al dr 600 ?
Where you got a new cylinder head bolt that has been broken? Did you buy a random one same size or made from exact specifications metals? Because as I think You still had to drill it and make another one, new thread for that bolt
I got a new bolt from partzilla and it was a genuine Suzuki bolt.
Can you name the exactly model of this bike?
It is not a SP45 right?
Very good Video!! Thank you
Greetings from Germany
for you ... is it possible to replace the valve seals without disassembling the cylinder head?
No you must remove the cylinder head. You need to compress and remove the valve springs.
What's the purpose of the plastic cap for the camshaft? why did they make a hole for a cap in the metal? also what direction should it go? it's not symmetric on its inner side.
That is a machining hole they made to complete the oil passage. The pointy end goes in the hole.
Does anyone by chance know the correct order for the head cover bolts? I’m told the service manual has them wrong.
It shouldn’t really matter just make sure your torquing them down evenly. The cover bolts don’t really do much at all.
I'm stumped! Just put the last bearing in and installed transmission, crank and balancer with dots in alignment. I operated the crank by hand via piston arm, felt some resistance and I'm getting a low whirring/buzzing noise. Sounds like it's between the balancer gear on the crankshaft and the case or bearing.
Definitely didn't sound like that prior to teardown. Am I missing a washer or is the crank too close to the bearing or something? I didn't take crank or balancer apart. I'm afraid to close cases until that's solved. Thanks!
What kind of bearings did you put in? If you take the balancer out and turn the crank over does it still make that sound? If you turn the bearings by hand do they sound different? There are no washers there so I would just eliminate things until you find out exactly what it is. You could also take the crank back out and just install the balancer to see if turning that makes the noise. Make sure the bearing have some lube too, dry bearings definitely sound different.
@@MarleyJaxGarage All new C3s, all lubed, no funny sounds from them. Mostly Nachi, 2 Koyos, 1 NTN 63/22 which the balancer sits in.
Sounds perfect without balancer. Is it possible it's just the gears meshing together and I'm overthinking it or should they be silent?
@@MarleyJaxGarage just figured it out. The balancer bearing wasn't fully seated. Left side was about 1/16" higher than right. Sounds much better now. Thank again!
@@igotakai5644 awesome glad you got it figured out man. Hope the rest of the build goes smoothly.
@@MarleyJaxGarage Thanks man! Just finished mating cases. Your method of heating up the socket or puller as a "slug" worked great for popping crank in and putting cases together. Barely any muscle needed. 👍🏽
I want the complete engine to Nigeria how can I get it
What the name of the blue tool at 13:26 ?
sorry if I disturb you ... but before reassembling the cylinder head, is it necessary, is it mandatory to rectify it?
I’m not sure I understand the question
@@MarleyJaxGarage have you rectified the cylinder head of your suzuki 650 in this video?
Hello. can you tell me the values for the tightening of the bolts 🔩, for the torque wrench? the values are the same also for the suzuki dr 600?
I go over all the torque values in the video but it will not be the same for the dr600.
@@MarleyJaxGarage you not have walue for dr 600 1986.....i look in internet.. but not there is
@@MarleyJaxGarage you are many good... bravo
Hey, at 24:07 is that a fully metal head gasket or a fiber/metal combo? The kit I ordered has the combo head gasket but came with the OEM all metal base gasket. Thanks!
The base gasket was all metal and the head gasket was the fiber/metal combo.
@@MarleyJaxGarage Awesome, thanks! Your videos and replies have been extremely helpful.
Finished everything yesterday and she rides super smooth. Thanks again for all your help!
@@igotakai5644 that’s awesome man enjoy the new ride.
COST REBUILD?
I am currently having trouble getting the sprocket and chain back on the camshaft. It is like someone stole a link from the chain when I wasn't looking. I took the clutch cover off to make sure that the chain wasn't kinked or anything but I just can't get the sprocket back on with the chain on it. Any idea what I am doing wrong?
You are trying to install it without the tensioner in place right? Make sure the tensioner oil plug is out of it and it should have plenty of room.
@@MarleyJaxGarage tensioner is fully removed from the bike too. I even took the rear chain guide out hoping that would help but no.
@@kebabbra is it the correct chain? Maybe count the links and verify. Are any of the parts new? Only other thing I can think of is that the cylinder or the head is not seated all the way.
Which state are you in? Pro job. My trusty DR has 54K so I'm gonna need to do a rebuild at some point.
I’m in Maryland. Can’t believe you made it to 54k, that’s awesome. You must maintain it really well. I would say it’s getting close to needing a freshen up haha.
@@MarleyJaxGarage It's the best tool for transportation. So many adventures I wouldnt/couldn't have gone on with my car. Lanesplitting is legal here so traffic is non-existent for me... I don't do much for maintanence other than religiously change the oil every 1000 miles or so. It needs a valve adjustment bad!
@@MarleyJaxGarage mine is a Freewind with 200K Kms I had to rebuild it a few years ago after a valve was dropped.
How did you learn all of this? Did you go to mmi?
No I am a self taught mechanic.
@@MarleyJaxGarage did you learn using the service manual, clymer book? I bought a used DR650 and have no idea.
dr 600.. dr 650, there is many difference?
They are completely different motors and depending on the year the dr600s are different.
@@MarleyJaxGarage suzuki dr 600 1986
3rd gear pinion can wear so its a good idea to check the condition and the gear selecter forks. Theres a 3rd gear mod by a gear engineering company thats far superior to suzuki part. Look on google.