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Old 11-10-2006, 05:19 PM   #1576
poohduck
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stock exhaust modification

Has anybody successfully modified the stock exhaust? I read somewhere that somebody thought you had to cut it open where the muffler meets the header pipe, and you can modify it in there. Has anybody tried this?
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Old 11-10-2006, 05:21 PM   #1577
Django Loco
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Quote:
Originally Posted by ram1000
Go to a 160 main jet and take out that pilot jet. Set the air screw to 2- 2.125. Shim the needle the same as a clip spacing on needles with adjustable clips.
Thanks for the tips RAM, I'm trying different combinations, doing EGA tests
and eventually will get it on the dyno. I'm running two shims. The slightly
richened pilot helps with backfiring and throttle response. Probably wastes
a bit of fuel but reduces backfiring. I've also drilled a hole in the slide. I'm setting the air screw for best idle, its around 2.5 turns at present but I've tried it in a variety of places when hooked up to the EGA. Percentages are
close.

Quote:
Originally Posted by ram1000
Remove the snorkle stuff on the air box. I run a stock pipe with high comp piston and 155-157.5 main and these settings. It runs great with no flat spots and gets 50 plus mpg when my wife rides it. I have found that mileage drops when your jetted too rich but remains close to stock when you get it right, unless your on it often. You'll burn your valves with stock main jet and a pipe.
What year is your DR? I've heard Suzuki made some subtle (and unannounced)
changes to ignition curves on '05 and newer bikes. According to Suzuki, these
bikes can run very lean....its how there are designed. The Carbs on '05 forward bikes also have a few changes Suzuki aren't talking about. Lean
lean lean. Its all about EPA, CARB and Euro lll. In stock form, they don't need
a lot of fuel.

You can bet we are near the end of the road for carbed DR's. FI is on
the horizon, Suzuki have been testing it on motocrossers for two years at least. Get ready, its out future. Me? I'll stick with my Carby DR for a few more years.

The fact your bike is running a high compression piston changes a few things
regards jetting, wouldn't you say? Higher compression = more heat, thus needs more fuel to maintain ideal combustion chamber temp. Anyway, this is how Mark explained it.

FMF informs me their Q2 pipe does not affect main jet requirements all that much. Maybe one jet size or no change. Opening air box does though. I now have pulled the snorkle off and found a big increase in HP. I've gone to a 145
main jet. EGA tests look good, plug color good. Dyno will be up next.

Quote:
Originally Posted by ram1000
I had a friend that burnt his at about 9k cause he would not up the jetting. He listened to ma after he rode my wifes bike. I suspect this is also the main cause of the base gasket going bad. THe bike runs too hot with stock jetting.
Have you run your bike on the Dyno yet? I bet it goes well with the high comp. piston! Mine is running well, pulling the front end up all the way through
first and 2nd gear just on power, just like my old KTM Duke ll.

Keep the tips coming....I'll try anything once.
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Old 11-10-2006, 06:11 PM   #1578
Django Loco
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Quote:
Originally Posted by poohduck
Has anybody successfully modified the stock exhaust? I read somewhere that somebody thought you had to cut it open where the muffler meets the header pipe, and you can modify it in there. Has anybody tried this?
I haven't heard of this for the DR. On some stock exhausts its possible to drill out the inner core or remove one of the baffles. It varies in difficulty with each bike. Some dirt bikes are pretty easy like the XR400, but stock KTM Duke exhausts are a nightmare. (Stainless)

I drilled out my old VTR1000 Honda using a hole saw and 12" drill to remove one of the three baffles in the can. Very slight pick up in performance, more sound. Of marginal overall value IMO.

You add a little sound but its unlikely pulling one of the three baffle sections
will add performance and certainly won't save much weight.

Most modern exhaust cans like the DR have a very complex and super well engineered design of baffles in three sections. I've seen them cut open.
They are all steel, some Stainless, which is a bear to cut. They are very
heavy and designed to last nearly forever.
There actually are pretty amazing considering how well they silence yet
still allow the bike to run pretty well. See any stock Japanese sport bike
for example or even the DR.

I'm sure others know more specifics on the DR. Probably could get an extra
stock can pretty cheap to experiment with. I'm keeping mine.
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Old 11-10-2006, 06:25 PM   #1579
poohduck
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Quote:
Originally Posted by Django Loco
I haven't heard of this for the DR. On some stock exhausts its possible to drill out the inner core or remove one of the baffles. It varies in difficulty with each bike. Some dirt bikes are pretty easy like the XR400, but stock KTM Duke exhausts are a nightmare. (Stainless)

I drilled out my old VTR1000 Honda using a hole saw and 12" drill to remove one of the three baffles in the can. Very slight pick up in performance, more sound. Of marginal overall value IMO.

You add a little sound but its unlikely pulling one of the three baffle sections
will add performance and certainly won't save much weight.

Most modern exhaust cans like the DR have a very complex and super well engineered design of baffles in three sections. I've seen them cut open.
They are all steel, some Stainless, which is a bear to cut. They are very
heavy and designed to last nearly forever.
There actually are pretty amazing considering how well they silence yet
still allow the bike to run pretty well. See any stock Japanese sport bike
for example or even the DR.

I'm sure others know more specifics on the DR. Probably could get an extra
stock can pretty cheap to experiment with. I'm keeping mine.
Thanks Django. It sounds like you are pretty happy with the stock. That suits me too if it isn't too restrictive. I didn't fancy paying a lot of money to replace a new exhaust.
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Old 11-10-2006, 07:34 PM   #1580
Django Loco
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Actually I have the FMF on my DR....it came with it. Bit loud actually.

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Old 11-10-2006, 08:35 PM   #1581
zzzzuf
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Motion Pro sells a exact replacement for the throttle tube...then
you can put what ever grips you want on. I think I paid
6 bucks for the tube.....Good Luck[/quote]

Is it the DRZ400 Motion Pro which fits the DR650?
Cheers
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Old 11-10-2006, 08:41 PM   #1582
Django Loco
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DRZ SM - DR Question

Does anyone know if DRZ400SM forks would in any way fit on a DR?
I believe these are 43mm?
Could I run the DR's 21" wheel? The SM has the big brake disk, wonder if the stock DR disc and caliper could be adapted?

Any help?

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Old 11-10-2006, 09:01 PM   #1583
wayno
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Quote:
Originally Posted by zzzzuf
Motion Pro sells a exact replacement for the throttle tube...then
you can put what ever grips you want on. I think I paid
6 bucks for the tube.....Good Luck
Is it the DRZ400 Motion Pro which fits the DR650?
Cheers[/quote]

Check this for sure but I bought at Suzuki dealer:
Motion Pro - P/N 01-0093

Hope this helps and on my receipt it says 9.99 so I was
a little off on that
Good Luck
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Old 11-10-2006, 09:56 PM   #1584
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Laugh Yep...

...that's the one...motion pro p/n 01-0093. The packaging doesn't mention the DR650 but it is the correct tube.


Quote:
Originally Posted by zzzzuf
Motion Pro sells a exact replacement for the throttle tube...then
you can put what ever grips you want on. I think I paid
6 bucks for the tube.....Good Luck
Is it the DRZ400 Motion Pro which fits the DR650?
Cheers[/quote]
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Old 11-10-2006, 11:42 PM   #1585
Max Kool
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Quote:
Originally Posted by Django Loco
Does anyone know if DRZ400SM forks would in any way fit on a DR?
I believe these are 43mm?
Could I run the DR's 21" wheel? The SM has the big brake disk, wonder if the stock DR disc and caliper could be adapted?

Any help?

DR-Z SM forks will fit a DR I believe. Both bikes have the same headstock bearings. But you want to use the stock DR 650 brake setup?
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Old 11-11-2006, 12:05 AM   #1586
poohduck
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dr650 jetting

Sorry for annoying you guys. I'm planning my dr mods. I have read through the forums here, and it sounds like with the airbox mod and standard exhaust, the recommended main jet size is 160. Is there any advantage in getting the dynojet kit instead of just buying a 160 main?
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Old 11-11-2006, 12:19 AM   #1587
Max Kool
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Yes, the needle and the spring will make the engine response MUCH better. Do it!
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Old 11-11-2006, 12:57 AM   #1588
poohduck
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Quote:
Originally Posted by Max Kool
Yes, the needle and the spring will make the engine response MUCH better. Do it!
Thanks Max. I'm looking forward to this
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Old 11-11-2006, 10:26 AM   #1589
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Quote:
Originally Posted by poohduck
Thanks Max. I'm looking forward to this
+1 on the DJ kit.
You also get several main jets so you can make changes with exhaust etc.

PS - get the extended air/fuel mixture screw while you're at it!

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Old 11-11-2006, 10:56 AM   #1590
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Quote:
Originally Posted by poohduck
Is there any advantage in getting the dynojet kit instead of just buying a 160 main?
Besides the better needle as was mentioned, you need to remember that Suzuki and DynoJet use different numbers for their jets. So, a 160 Suzuki jet is different than a 160 DJ jet. So, when going on someone's recommendations for jetting, remember they are usually referring to DJ jet sizes, but not necessarily always. With the DJ kit, you know what you are getting and know it works.
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