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I’ve got a 2000 DR650 with 23k miles that I’ve owned for the last 4 years. I consider myself pretty capable mechanically (rebuilt/restored other bikes as well), but this problem has me stumped. Here’s what happened: The bike was running normally, then sat for two months while I traveled (a friend was supposed to ride it, but oh well). I got back, put on some new brake pads and took it for a spin to bed-in the brakes. The bike was running well, I was having fun, and I sped up to 90mph on my way back home (it’s got a modified airbox, rejetted BST40 carb and GXSR exhaust…normally does 90 easy). All of a sudden the motor starts cutting out, I back off the gas and pull in the clutch, and the motor dies. Tried to start it again on the side of the road, no luck. When I try to start the bike, the starter motor cranks, the piston cycles, I have spark, but it will only fire for a millisecond and then die (maybe on just one stroke) after cranking for 4-5 seconds. Here’s what I’ve done so far: - Did a leakdown test, looked great at 95% - Changed oil, no metal shards found on magnetic drain plug or in pan - Cleaned carb - Drained old gas from tank, replaced with fresh gas and added fuel stabilizer - Adjusted valves (they were a tiny bit loose) - Replaced spark plugs (checked them on the bike, getting consistent bright blue sparks) - Tested resistance of pulsar coil, power coil, and ignition coil (both primary and secondary) - all within spec - Battery tested and in good shape After all this, I still have the same result when starting the bike. I haven’t tested the CDI box yet, but I think that’s the next thing on my list before tearing into the motor. Any ideas of where else to go from here? This really has me banging my head against the wall...
I hope you all have been out riding and enjoying spring. I got back into the hare scramble racing scene over the weekend after a three year hiatus and had a blast. Today, I just want to share a quick tip and start a discussion on preparatory things that help shorten the time it takes to do complex maintenance tasks, such as rebuilding an engine. Quick Tip Prior to turning a wrench carefully look over the service manual scanning through all the applicable procedures and subsystems. If I’m working on an unfamiliar model, I find it is helpful to jot down a rough outline of the disassembly sequence. This saves me time in the long run as I don’t have to rely as heavily on the service manual or continually flip through various sections. Another option is to use post-it notes to bookmark each relevant section in the manual. Mark the post-it notes with numbers or headings so you know where to turn to next. Earmarking or bookmarking the torque tables is also a huge time saver no matter the task. Be sure to scan through the manual as well to identify any specialty tools that are required that you may not have. Discussion Points What other preparatory things can be done to help speed up the major maintenance process? Is there a method to your madness or do you dive right in? Thanks for reading! Paul https://www.diymotofix.com/
Today I want to share a quick tip with those of you who are working on your own engines but just can’t justify buying a set of piston ring compressors. It’s entirely possible to make a perfectly good ring compressor from materials you can get at the hardware store. All you need is some plumber’s pipe hanging tape and a hose clamp that is sized according to your cylinder bore. To construct a DIY ring compressor from plumber's pipe hanger tape you will need to determine the length of tape required. This is easily done using the following equation for calculating the circumference of a circle. Length of Tape Required = Piston Diameter x π (Pi) When the tape is wrapped around the piston tightly, the final length may need to be reduced slightly so that the ends don’t butt together. Once the tape has been cut to length, make sure whichever side of the tape will be contacting the rings is smooth and free of little plastic burrs that could catch the rings. Simply lube up the tape, tighten down the hose clamp, and you are in business. Do you have a tip that makes compressing rings easier or cheaper? If so, leave a comment below! - Paul If you enjoyed this tip and want access to more like it, check out my book, The Four Stroke Dirt Bike Engine Building Handbook. On the fence about the book? Check out what other riders are saying: Thumper Talk Review Available at: Amazon.com DIYMotoFix.com