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Old 03-24-2013, 10:21 PM   #16
VooDooDaddy
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I thought this thread was about a 790cc build?
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Old 03-25-2013, 12:45 AM   #17
BergDonk
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Looks good, keep it up
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Old 03-27-2013, 10:26 AM   #18
refokus
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I am in to follow the rebuild. Looking forward to the final results.
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Old 03-27-2013, 06:09 PM   #19
DisTech OP
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Special tools

Thanks guys!

Here I was happy with my flywheel puller just after it made that metallic TINK noise popping loose on the crank. Split the case, piece of cake (I think to myself).


Well not so fast! Right behind the flywheel is a wonderful ring nut (#14, thank you Suzuki!!!) that according to the manual also requires a special tool. Google results show the ring nut socket costs more than the flywheel puller! Pfft, special tools, someone must have a workaround. JamminJay on ThumperTalk did.


$60 flywheel puller and $8 ring nut tool (pre "machining").


Looks like Jay also had a mill which I don't so this could get ugly.


Uuhhhh...


Victory!!!
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Old 03-27-2013, 10:53 PM   #20
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2013 WR250R

SUZUKI DR650SE INFORMATION INDEX
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"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 03-28-2013, 03:52 AM   #21
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Old 03-28-2013, 08:28 PM   #22
Reposado1800
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I wonder how many people just use a punch to get that ring nut off.
This is probably going to be the build thread of the year. I can't wait to see it go together.
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Old 03-28-2013, 09:14 PM   #23
DualSport650
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Oh, man.

I gotta see this build!!!

I wonder if I could 790 my Honda XR650R? LOL!
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Old 03-29-2013, 10:09 AM   #24
rch10007
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Quote:
Originally Posted by Reposado1800 View Post
I wonder how many people just use a punch to get that ring nut off.

I wouldn't suggest it. IF someone did get it off with a punch, they either tore up the nut and would lie about it or they are the luckiest SOB in the world or they are just plain full of shit. The first time I rebuilt a DR motor, I tried everything short of a blow torch to get it off. Finally, i broke down and bought the tool. I figure if I'm going to be rebuilding these things, it pays to have a good tool. It takes 2 secs to remove, replace and torque that nut with the proper tool. Who wants to risk f'n up a brand new motor over not having the right tool. I know we all like cheap, but sometimes, you get what you pay for.
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Old 03-29-2013, 07:34 PM   #25
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Case, bearings and transmission

I did whack the ring nut with a punch and hammer a few times, but it's pretty soft and was taking too much damage. So I stopped and searched for the proper tool. Judging by the amount of force it took to remove it, the ring nut would have been destroyed using a punch.

Splitting the case for the 790 upgrade is not necessary. I'm doing it for three reasons.
  1. Last year I took my clutch apart too far and wrecked the little retaining wire that holds some stuff together that you normally don't touch. The old wire was consumed by my transmission... hard shifting... whining noises... etc...
    I replaced the retainer wire and flushed/cleaned it out as best I could and everything seemed fine, but it been nagging me as to what was left in the transmission.
  2. Check the bearings (see #1).
  3. Check if 3rd gear getting ready to explode!

On with the case!


Another special tool.


All clear.


Flip it and split it.


It actually came apart easier than my 350's.


And clean too!



1Countershaft/Gear, 1 St Drive
6Gear, 5 Th Drive
3Gear, 3 Rd Drive
4Gear, 4 Th Drive
2Gear, 2 Nd Drive
15Gear, 1 St Driven
27Gear, 5 Th Driven
21Gear, 3 Rd Driven
26Gear, 4 Th Driven
18Gear, 2 Nd Driven
14Drive Shaft

The 5th drive gear has some minor spalling, but rest look fine.

  1. What remains from that clutch retainer wire? Nothing!
  2. Bearings are tight and free spinning. As far as I'm concerned they are good to go.
  3. Gears look good too.

I'm putting the case back together in the morning.
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DisTech screwed with this post 03-29-2013 at 07:40 PM
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Old 03-30-2013, 08:44 PM   #26
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Case, piston & jug

Clean an reassemble!


Align the dots!


Manual says position shifting cam like this so the forks will fit easily into place. It works!


This was pleasing (can't do this with DR350 guts on thier side) and looked cool.


Case sealed!


Was cruising right along, then "What the...!!!" (see arrow). Did I leave out a dowel! Frantic looking at pictures I'd taken, manual searching, Googling exploded views, nothing...


Decided to push on and when I dropped the starter torque limiter in place it was super sloppy. Well, well... not a dowel, it's a sleeve.


A big thanks to planemanx15 for having the guts to post the highs, lows and highs of his DR790 build (DR650 790 Big Bore Installation and Review) .

A couple things that have come from the lows:

Notes:
  • Top ring is gray and has a dot indicating the top.
  • Second ring is black and has a dot (more like a circle) indicating the top.
  • The stock piston has a dot on it that indicates the front. The CP piston does not and their install instructions only talk about ring gap and cylinder honing. Eyeballing the piston makes me think it is symmetrical and can go either way and I would expect the instructions to say something if it mattered. However, I found one forum post that said the pockets were different and the CP on the bottom of the piston goes to the exhaust side. There is a CP marked on the bottom so I oriented the piston with the CP to the front.
  • The oil ring and its side rails were by far the hardest to get in the jug (without ring compressor).
  • Ring gaps positioned according to the manual.
  • The CP piston pin circlips are at least three times as beefy as the stock ones! A challenge to install.
  • Double metal base gasket!.


Got the jug on and that's where she sits tonight.
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DisTech screwed with this post 03-31-2013 at 07:33 AM Reason: None yo
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Old 03-31-2013, 02:06 PM   #27
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Top end

One of the notes from ProCycle is that the manual has a typo. It's true, it does and I thought it was funny that it specifically tells you to put the bolts in the "correct position".


New cam, old cam.


TDC and line up the timing chain marks.


Suzuki molly paste and Red-line grease.


790cc!


The gear shift cover gasket did not survive the procedure and a new one is on order.
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Old 03-31-2013, 06:42 PM   #28
rch10007
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Stock carb?
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Old 03-31-2013, 08:26 PM   #29
refokus
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Nice work, keep it coming. I am interested in hearing the final results on the build.
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Old 03-31-2013, 08:30 PM   #30
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Originally Posted by rch10007 View Post
Stock carb?
TM40, FMF oversize header and GSXR exhaust.
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