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  1. Hi guys, First post here, hopefully one of you guys can help me out. I've already checked the forums, as well as the haynes manual and carb schematic - no luck. I just rejetted the carb on my 06 DR-Z400 SM (stock mikuni bsr36 carb). After putting it back together, I found that I'd left the following part out (circled red in photo - small plastic part clipped on top of main jet. Photo taken on spare carb) Can anyone tell me what this does? The bike seems to be running fine without it. Unless this is going to cause any damage, I probably won't be pulling the carb to replace this any time soon. Cheers, Jake
  2. I'm looking at picking up a used DR650/KLR/690 Enduro for the lady friend and there happens to be a cheap DR650 in my area for sale right now. The potential problem? It's a model year 2000 with less than 4500 miles on it. I have a 2013 DRZ-S that has about 6000 miles on it and I feel like that's borderline neglect so a 2000 with even less has me concerned. What should I look for or be concerned about that I can check in someones driveway. Would it be worth it to trailer it somewhere and have it checked out professionally? I'm new to the area and therefore don't have a "trusted mechanic" and the nearest Suzuki dealer is ~2.25 hour drive away. Edit: I should add that I've got probably 30 hours seat time on a 2007 DR650 so I know roughly how they should feel.
  3. So when rebuilding my carb on my 99 DR350SE I realized I have a problem. The metal tubing that spans top to bottom on the right hand side of the carb is broken at the top threaded connection. First of all, what does this do? I assume its part of the pilot circuit but cant really find a good schematic or free service manual. Secondly, does anyone know where I can source this part? It's not in any of the rebuild kits, nor is available through BikeBandit or the likes. Any ideas? I have attached a picture that shows the part in question. Thanks!
  4. Hey everyone, I recently came across this 2006 dr 650 with 12k miles and was looking for some input about the bike and if everything looks and sounds right. I wasnt sure if this is the right sub to post in so mods feel free to move it. Im coming from an 04 yzf250 and was looking for a larger trail bike that i could also commute to work on (15-20 miles). Im 6' 190. I realize that this bike is very different from my 250 but after watching numerous videos and reading an ungodly amount of forum posts and articles this seems to fit the bill for what im looking for. If anybody has any suggestions, prior experience with a 650 thumper or tips let me know! Thanks Video :
  5. G'day everyone, I'm looking to identify a carb on a project bike I've recently acquired. I've searched high and low and I just need a confirmation on what this may be. It's off a DR400. It says 'Mikuni Made in Japan' on the body of the carb. This is a knowledgeable forum, I'm sure one of you will recognise it in a heartbeat. Regards, Jaymin
  6. Anyone upgraded the headlight on a dr350 and if so, what did you use?
  7. Hello all! My name is Miles and I need some help gauging what to expect for condition/"reliability" you could say, of my DRZ400E for cross country travel! I am looking into traveling the Trans America Trail. I'm from Rhode Island and found an alternate rout where I can start on the West border of Connecticut. Ending in Colorado, to Nevada, then California; and cruising something along the lines of RT66 back. [just for reference, don't mean to ramble] The Machine: 2003 DRZ400-E ~6k miles total - 5k lightly ridden, never seen dirt - 0.8k %100 hard off road [past year] Frequent Oil changes, Air Filter changes {I ride with the guy I purchased it from nearly daily. He was good about maintenance on the regular, but also pushe the bike in the woods just as much!} Front and Rear Suspension rebuilt, carburetor rebuilt all last year Stock everything except FMF power bomb header and exhaust muffler, and Vapor Trail Tech, lights + fork socks Expected Maintenance: Top End Rebuild, Timing, Valves adjusted [Have not done compression test, but i would expect new top to be necessary] obvious things such as Brake Pads, Fluids, Chain/Sprockets, Tries, Heavy Tubes From this information, And Any You Can Think Of To Ask, does this DRZ have potential for the Trans America Trail; a ~6'000 dirt, then ~4,000 road return trip?! Or would I be better off selling it for a newer model? Thanks! -Miles
  8. Bought new in 1997, my Suzuki DR650 motorcycle in 2014, with 20500 Km on the clock experienced unpredictable catastrophic 3 rd gear disintegration. Eventually in December 2016 the Small Claims Court of South Africa, with Suzuki Auto South Africa defending,the court awarded me my damages claim for the repair of my Suzuki motorcycle. For more details visit www.harryterezakis.blogspot.com
  9. So my negligence has left me with several hooked teeth on the balancer drive sprocket (directly behind the flywheel on crankshaft). I need some help on replacing it. 1.) The manual states that i need special tool 09917-23711 (ring nut socket wrench) in order to remove the old one and torque down the replacement. I've seen the Suzuki branded tool for $114 - 180. There's also an undbranded one on ebay for $60. https://www.ebay.com/itm/Suzuki-Cranksh ... 2630!US!-1 If I can help I'd rather not have to purchase a tool I'm only going to use once. Does anyone have one they can lend me if I put a deposit on it? 2.) The manual also states that I need a Conrod Holder #09910-20116, I'm guessing that would stop the crank from spinning during removal and reinstallation. Is there any way I could get around this as well? I've seen a youtube video of someone locking up the piston by feeding a shoestring through the sparkplug hole. I'm not sure I trust that not to go wrong and have dirt/fabric in my cylinder. If I put the bike in gear and ratchet strap the rear wheel to the frame or something more stout, like a tree, would that prevent the crank from spinning? 3.) Also part # 12662-37402 Suzuki balancer drive sprocket usually runs about $130 new. Does anyone have a used one in decent condition they'd be willing to cut me a deal on?
  10. 1991 dr650

    1991 dr 650

    hello i currently have a 1991 dr650s , tm 40 carburetor one millimeter over bore pistion. the motor randomly started knocking from the bottom end but it does not seem to be the crank bearings or crank, checked the valve lash pulled the clutch out nothing seems to be out of place any ideas of what this could be
  11. ianv

    94 dr350 clutch

    Hey everyone new to the fourm, in a really weird situation. burnt the clutch on my dirt replaced it, everything is in right and now the clutch wont disenage, the clutch rod is all play it dosint wanna pull the plates, i have no idea what to do please help, i called a mobile mechanic, he didint wtf he was doin so i cant trust anyone please help will attach video if needed
  12. Hey everyone. I've just started to ride my dr650 again after about a 6 month break. As I was taking it down a back road I started to hear a rattle coming from the left side of the bike. At first I could only hear it in 1st gear, after I got back to the main road I could hear it in the lower gears. Where there wasn't a whole lot of noise hiding it. It doesn't do it on smooth roads, and it doesn't do it while idling. At first I thought it might be my home made foot pegs. Alas it still did it even as I was holding them still. Also on the left side the engine is getting very hot fairly quickly. I'm currently waiting for the engine to cool off to knock things aroubd and see if i can find something loose. In the meantime I've been looking up the symptoms and some posts mention the heat shield, but since it isn't rev specific I don't think that's it. Any ideas anyone?
  13. I was riding my bike around the neighborhood when all of a sudden I hear a clunk and the bike shut off on me. I tried kick starting it back up but the kickstart lever was stuck and wouldn’t move. I kicked it hard and got it to move a few inches and it sounded like stuff was moving in the motor but it just seized up again (picture shows where the kick lever will not go down any further). The bike has 16,400 miles on it and I just got it 4 weeks ago. It has been running great for the 500 miles i’ve put on it until now. To me it sounded like something in the motor decided to die but I’m really not sure what’s going on. Could It just be the kick start lever or did the motor blow? Any information or ideas are greatly appreciated.
  14. so I am undecided between DR650 DRZ400 anyone has any experience how much I can get it below MSRP? the DR650: BASE MSRP◊ $6,699 + DESTINATION CHARGE $365.00 the DRZ400: BASE MSRP◊ $6,699 + DESTINATION CHARGE $365.00 can they remove destination charge and even go below MSRP? if so how much do you think? I was hoping to get it @ about $6100 OTD so that would be removing destination charge and getting the MSRP to about 5800. is that too little for a dirtbike? I can understand for ATVS that cost 13k 14k and shed off 1000, but unfamiliar with this low (negotiating wise)
  15. Does anyone have a wiring diagram for a dr100? Currently have my drz motor down for a rebuild and have a spare dr100 motor I bought a while back. It came with all the wiring but it was a rat nest to say the least.
  16. Hey all, New to this forum because it seems like one of the best. little backround, I grew up trail riding and raced mx a bit with my cr80 (some of my favorite childhood memories)... hiatus for a number of years besides rippin around at the cabin, had an R6 for a 2 or 3 years and then I've been traveling for 4 years.... planning to settle back down in Mn for spring summer falls and want a bike to get around and tear up as much dirt as possible as I explore. goal is to enter some hare scrambles next year to start getting back into racing a bit but till then it will be my way to get around and my bike to train. I am probably looking for the impossile and so my heads spinning with all this information... but something around the 400cc seems like a good size bike but pretty much no options on cl at the moment. 250cc would be a blast and great to get back to dirt but when I cruz to see family and friend in other states, will I hate my life after an hour on the highway? I'm drawn to the xr650L with the mods and available parts but is it going to be a monstrous challenge to bring back and hone in my skills with a 350lbs bike? I'm 6'1" 175 lbs and train 3 days a week rock climbing, so I am in good health and great shape so I feel up to the challenge but maybe someone similar could share their experience/expertise? Massive failure jumping to a brh or were you happy to have something to grow into? budget is flexible but looking to spend 1-3k on something ready to go, reliable, street legal, and can hang off road. I'm looking to beat it up quite a bit so dont mind something older if it can hang. Pretty much sold on the Xr650L but thought this would be a good place to check myself before I wreck myself... literally... 2003 xr650l $2400 (is 20.5k miles too high??....they seem to run forever) I like that some of the mods I want are done already and it seems like a reasonable price if the splines on the countershaft sprocket are in decent shape? figure when the motor needs major work done on it bore it out and do some of the other more intrusive mods? 2007 xr650l $3300 extra parts and some mods, newer, lower miles crf230L $3000- fun size, but its it going to be a slug without spending a bunch more on mods? Am I going to want something bigger soon after? 03 KTM 625 SXC - $3300 seems like a solid option as well...??? Thoughts? comments? Thanks all!
  17. Hi All, After searching and digging up info on this site for a while now, it's finally time to ask a question. First, I want to thank everyone for all the information I've found on here. It's been a huge help in bringing the DR back to life. As the title says, I have 1994 Suzuki DR350SE (electric start) that is having some starting troubles. It's actually my roommate's bike and it's been sitting for at least a year. He agreed to pay for all the parts and to let me ride it if I got it working (he's gone every summer and fall), so I read through the FSM and started with the basics. First thing I did was replace the battery and luckily it fired right up. After that, I put fresh fuel in the tank, swapped out the old cracked fuel lines for new ones, Adjusted the chain tension, changed the spark plug, changed the oil / oil filter, cleaned the bike up, and went out for a ride. It ran great accept for a lot of popping on deceleration when in gear, but after I got the bike good and hot and shut it off, it wouldn't start again (just kept cranking). I let it sit overnight and it fired up first try the next day. I took it for another long ride, turned it off and then tried to start it again. It fired up a second time, so I went out for another rip around town, came home, turned it off, and no dice. Since that day, I've taken the carb apart (which was way cleaner than expected), checked the jets, checked the float needle, etc, and gave it a quick clean. I put the carb back in and went to start it and it cranked but didn't turn over, so I pulled the plug and checked for spark. Nothing.. Broke out the multimeter and checked resistance on the ignition coil, pickup coil, and source coil. All were within the specs in the FSM. I cleaned the electric connectors which all looked a little dirty, but okay. I also checked the kill switches for the clutch and kick stand, thinking that one would be the culprit, but it appears that both have been removed and bypassed by the previous owner. At the end of a day of troubleshooting, I put everything back together and found a hill to try a bumpstart. It bumped on the second try and I went around for a quick ride. Came home, turned it off, and it wouldn't start. As it did the last few times, it would crank and crank and crank and not fire up. Battery still reads high 12v, plug doesn't appear to be wet, and the float bowl has plenty of fuel in it. I'm sure i'm missing something, but the only other thing I can think of that's left is the CDI unit... I've read that the ignition coil can be bad even though it's within spec, but it was replaced about a year ago. Thanks in advance for any suggestions. Looking forward to getting this thing back on the road!
  18. I just installed my new Acerbis 4.25 tank on my 1991 DR350s and I’m having some problems. This tank has 2 petcocks and I put both to the on position when running the bike. It started up and idled fine, but when I gave throttle it sputtered and died immediately. Should I only have one petcock on at a time? I also had to get a new main jet for my carb because my old one was lost in the garage after my table was knocked over. The shop gave me a 135 and said it would be fine. I have the airbox mod and a supertrap, would this new jet be affecting the bike under throttle? There are a lot of variables that could be causing this so I thought I’d ask all the questions I have so I have a better idea of what to focus on. Thanks
  19. Hey fellow DR650 owners. New to the forum so sorry if this isn’t the correct spot to ask this question. I recently purchased a minty fresh stock 97’DR650 and love it! Put on some tusk Dsport tires which has been a great improvement over the trail wings. The only complaint I got is I have 520 15:42 gearing which seems very tall and makes it more challenging for off-roading and I’m concerned about excessive clutch wear. Seeing I’m due for a new chain soon I figured I’d play with some different sprockets. I know the popular is to just drop a tooth on the CS sprocket to a 14t but I would like a little more range with out using a 13t for added chain wear. I like the idea of a 45t rear with a 112 link chain so I can change the CS sprocket from a 14t, (off-road)15t, (similar to popular 14t:42t for around town and mild highway) and 16t(similar to stock for long highway cruises) . I can’t seem to find a 45t rear sprocket? Procycle has a 46t rear sprocket. Does anyone else use this setup and swap out the CS sprockets to have the ultimate dual sport ? Any issues with running a 46t rear and 14t,15t and16t? Close tire and chain clearance? Excessive wear?What is the correct chain link to run all 3 CS sprockets? Any other good sprocket combos that will achieve similar ratios for good off-road and highway capabilities with just a simple CS change when entering or leaving the trails?
  20. Hello, I broke my clavicle in March following a accident. It was a mid shaft fracture with mild displacement, no surgery. I wore a sling for about 10 days and then I stopped. I started getting pins and needles feeling in my hand occasionally especially if I lifted anything or if I was poking ny clavicle. After 6 weeks I went back to my manual labor job, and at 8 week I had to lift some heavy stuff and my shoulder started to hurt. Then at 10 weeks following some light shoulder exercises with a 5lb weight I got bad pins and needles feeling in my hand and fingers and cold feeling in my pinky and ring fingers which lasted for about a week. Now my shoulder hurts especially in the back shoulder blade and also AC joint and bursa area. Also the pins and needles feeling in my hand and fingers comes and goes throughout the day. Has anyone else here experienced this following a clavicle fracture? I see my doctor in middle of July. Is there anything I should do or not do until then? Is it ok to keep working? Im not asking for medical advice but does anyone have a opinion on whats going on with my shoulder/hand? Thank you.
  21. Hello guys I'm new here. I just want to get more information before I decide what to buy. I like the drz400 but the seat height is like 930mm or 950mm ? I'm 5ft8 (33in inseam) 35.5in with boots My friend got drz400s and I tried to sit on the seat Like this one there is actually no issue but I can barely touch the ground with my full foot I stand with my toes Is there anything I can do to decrease the seatheight by 2in's or more? that would be cool Or I should get drz650 which is the seat length is 880mm ? I really didn't like the 650
  22. Hey guys idk if my last one posted or not but I’m looking for the bottom end rebuild kit for my dr350s looking to do big bore on the top end but can’t find anything for the bottom not really looking to piece it together but will if needed to and has anyone gotten the dominator round silencer exhaust if so how do you like it
  23. Trying to get locate a replacement key ignition switch for my 96 DR350SE. Everything on eBay seems to have a different wiring harness pattern. The one I have looks exactly like the attached pic and url: https://www.cmsnl.com/dr350se-1996-t_model13183/switch-assy-ignition_3711003d01/ A lot of the ones on eBay don’t have the separate black w/ yellow stripe wire outside the plug. Anyone know where I can get one of these in the pic/url thanks,
  24. so I live in colorado and I ended up buying a KLX250. seems it struggles to go passed 65MPH on 5th gear (my klx has 6 gears).....so im in search of another bike!! kinda.... now..for my klx250 its awesome on trails want to keep it...but cant barely travel on highway. But what if, I add a 15T sprocket in the front? can I then cruise at 75MPH? or should I even down the sprocket to give me more torque and maybe my 6th gear can be my 75 - 80mph? since it seemed my klx was stuck at 60mph on 5th gear giving it full throttle @ 8000rpm out of the 14,000 it has or am I better off with a drz400 or even a dr650 and adding a 15T? i dont plan on doing advanced trails...just service roads and chilling out in the mountains. maybe the most technical would be something like this below...... Any recommendations?
  25. Is there any way or tricks to lighten up the throttle on my 1980 Dr 400 have put new cables on but still feels heavy compared to my modern Ktm.can you do anything with the spring on the outside of the carb maybe?
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