Official Dual Sport BS Thread

Interesting. I'd buy one! My cousin had a CRF450R which I rode around his neighborhood a few times. It was one mean machine.

 

HELP WHATS A FAIR PRICE FOR A 98 DR650 MOTOR COMPLETE
WITH 18K
????
I MIGHT HAVE FOUND ONE?

 

AND SO IT BEGINS

 

so today i started the tear down....
stay tuned

 

Just a rebuild or are you boring it out also?

 

motor swap.....
pretty sure i blew third gear....
got a new old donor motor.....
i need to swap out my starter and torque limiter and get her up running again
then i will tear down and see what actually happened to the motor
if its not wasted the case / crank i might split the case and do a 790 kit on her.....

 

That would be a LOT of fun (if you did the 790 kit). That's gotta be a wild ride! Good luck with the process, hopefully no hidden snags.

 

yea i was already getting my ass kicked getting the exhaust bolts out....
ended up using a 1/2" impact gun.....

any tips on new bolts? for exhaust
stainless, or steel or

 

Honestly, I haven't ever had a problem with them. I'd just get new steel replacement bolts and plaster them with neverseize. Last rebuild I did was on a 1973 bike and it all actually came apart very nicely, nothing was rusted in place.

 

yes i am trying to get the motor swap done by this weekend while the weather is warm.......
then i can swap the rest of the parts over later...

 

I used a copious amount of anti-seize on the header bolts. Never had a problem going forward.

Out of curiosity, did you have any tell tale signs that your third gear was about to go? I know that was a major design flaw with the DR650s and it was prone to happening randomly at anytime. There is a thread on thumpertalk.com where people are trying to collect info on bike year, mileage, and condition when it went.

PS, make sure you secure this shit out of the NSU bolts when installing new engine.

 

no warning what so ever
riding down the road when everything just locked up...
kinda felt like the chain came off....but then the sound of marbles in the gear box

 

update
so i got the old motor out today and the new "old motor" in place
i still need to hook up carb, oil lines, starter,cct,brakes, clutch cables, ect
and i need to swap out the starter gears.....
i hope to do some of that tomm before the rain starts
the motor was a breeze to remove and install by myself ....
within 20 mins i had all engine mounting bolts back in place
i took the motor out of the left hand side....with bike on kickstand
lots of sandwich bags and tape to label everything.....
here are some pics from today



i could not get the starter out without removing the CCT.....so out it went.....
i didn't try to remove the cap..but maybe if you did that you could gain enough clearance...but idk and did not try




here is the gasket......its the broken motor....on the new old motor face is clean and i have a new gasket...


here is the CCT removed


lots of sandwich bags....ahaha


and she is out...not as bad as i thought it was




i was thinking of mounts to mount them both hahaha


then the insane clown posse showed up for a wheel bearing swap and drinking began and bike progress came to a halt



to be continued

 

update day 2
got allot accomplished today
i started by making these




then i installed the starter and cct

then i set motor at TDC and removed the CCT and then re installed it....

then i adjusted the valve clearances while i was in there....


i opened the left cover and found that it already had a starter clutch gear
also found that this engine had a failure of said solid gear in the past and someone welded it back....
that was not disclosed to me upon purchase...
but it looks to be fine and a nice weld job too...


i cleaned up the surface rust.....




then these gaskets KICKED MY ASS
omg what fresh hell in getting the gaskets off.......like almost 2 hours errrrr


also found on the old motor that the oil filter cover is cracked :maybe it happened during shipping idk
but no problem as i have a nice donor motor


then i fished out the damages
it looks like something imploded unsure if its 3rd gear
but it a gear......




then i got the oil lines installed as well as the carb, rear brakes, levers,exhaust, just about everything except for wiring and tank......

hows the throttle response look
http://youtu.be/j2Lfq2hEq58

i was to wet and tired and beat up to try n rush to finish job....
but maybe tomm if i can get home early......

any tips or advice before i try n fire her up
i did not add any oil today as i wanted the loctite and gasket sealant to cure up......
i am also looking for a new oil cooler.....

 

What's takin so long?

 

removing the fucking gaskets
that's what

omg i was ready to through out the side covers.....
took me forever
im old......

 

IT'S ALIVE!!!

 

NOW I NEED TO DIAL HER IN......
3 MONTHS NO RIDE BATTERY WAS ALMOST DEAD AFTER THE INITALL 2 MINS OF CRANKING TO PUSH SOME FUEL THROUGH....
TIRES WERE ALMOST FLAT WHICH I DIDNT CHECK AS I CRUNCHED THE THROTTLE

I NEED TO REPLACE SOME EXHAUST GASKETS AND OVERALL REROUTE SOME WIRING.....

THEN HMMM

 

ON A LONG SHOT
ANYONE HAVE A CASE SPLIT-ER I CAN BORROW?