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Old 04-12-2013, 06:48 AM   #75691
mattomachu
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Location: Portland, Oregon
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DR650 Magneto bolt...right or left hand threads?

Just bought a 2003 DR650 It has 6000 miles on the dial. It wasn't running when I bought it last week. I put a new battery in and it fired up. I don't think the valves have been adjusted since the first owner. This is where the chaos begins. The small cover on the left side with the allen key was stripped into a complete circle. I tried to use a chisel and it wouldn't budge. I ended up taking the entire side cover off. I then drilled the little cover and installed some bolts to to jimmy the thing off. Finally got the thing off, but in the process the starter clutch gears came out and the two washers fell out. I tried to catch them, but they eventually slid down in the bottom of the engine. So I don't think it's a good idea to leave them down near the oil drain...I tried to use a few different things to no avail to try to get them out.
If I remove the magneto I'm almost positive that I can use a small pick to retrieve them. Has anyone else had to deal with this chaos? Which direction are the threads on the initial 17mm nut? I tried both directions w/o a budge. Anyone have a lead on a magneto puller? I'll pay for shipping both ways...
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Old 04-12-2013, 07:15 AM   #75692
planemanx15
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Does anybody have the Jesse's midpipe for a Hayabusa muffler that they're looking to sell? Standard header size
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Old 04-12-2013, 08:02 AM   #75693
sandwash
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Try kientech or Two brother's wesite
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Old 04-12-2013, 08:09 AM   #75694
Emmbeedee
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Quote:
Originally Posted by barko1 View Post
I'd try inserting a phillips into the tube, as far in and as big around as will fit, then push the handle to turn it. I think that lessens any chance of deforming anything, YMMV
I was looking around for something which would fit nicely in there when I thought I'd give one last try to getting a hose to fit without all that unpleasant carb removal/heating/twisting/swearing/breaking/cursing/searching for another carb which would have been inevitable, considering my luck so far this week...

So I think I'm finally happy with this:



I think the most important part with making this line work is to not have the hose too long. When I first tried it, the bend at the top of the carb connection was quite tight, and it was solely because the hose was too long and needed to make more of a tight curve to go back down towards the Pingel.

The hose I ended up with is probably only 3" long, but it has no tight bends.

Yay!
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"The motorcycle, being poorly designed for both flight and marine operation, sustained significant external and internal damage," police noted.
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Old 04-12-2013, 08:13 AM   #75695
thump!
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Quote:
Originally Posted by mattomachu View Post
Just bought a 2003 DR650 It has 6000 miles on the dial. It wasn't running when I bought it last week. I put a new battery in and it fired up. I don't think the valves have been adjusted since the first owner. This is where the chaos begins. The small cover on the left side with the allen key was stripped into a complete circle. I tried to use a chisel and it wouldn't budge. I ended up taking the entire side cover off. I then drilled the little cover and installed some bolts to to jimmy the thing off. Finally got the thing off, but in the process the starter clutch gears came out and the two washers fell out. I tried to catch them, but they eventually slid down in the bottom of the engine. So I don't think it's a good idea to leave them down near the oil drain...I tried to use a few different things to no avail to try to get them out.
If I remove the magneto I'm almost positive that I can use a small pick to retrieve them. Has anyone else had to deal with this chaos? Which direction are the threads on the initial 17mm nut? I tried both directions w/o a budge. Anyone have a lead on a magneto puller? I'll pay for shipping both ways...
Yeah, people just love to tighten that plug to the point it can't be removed. There's an o-ring there. It just needs to be snug. It doesn't have to be tightened down like the drain plug on your grandfather's '49 Ford. Mine was like yours when I got it but I was able to remove it with a hammer and punch.

FWIW, while it makes the task easier, it is possible to adjust the valves without removing that plug. It's a single cylinder engine after all. You only have to find TDC once.

Good luck fishing out the parts. If it were mine, I'd try using a magnet attached to a flexible wire.
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Old 04-12-2013, 08:22 AM   #75696
RichBeBe
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Tanks and carbs

I have an Acerbis tank and a FCR on my bike. I can run my bike to literally dry and have to push it. How do I know? As I was trying to test how far I could go on a tank, and was on reserve not on (dumb ass that am I). Luckily i was able to lay the bike down to get the fuel to the left side, got another mile or so and it died about 100 yards from a gas station.
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Old 04-12-2013, 09:08 AM   #75697
RichBeBe
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Tanks and carbs

I have an Acerbis tank and a FCR on my bike. I can run my bike to literally dry and have to push it. How do I know? As I was trying to test how far I could go on a tank, and was on reserve not on (dumb ass that am I). Luckily i was able to lay the bike down to get the fuel to the left side, got another mile or so and it died about 100 yards from a gas station.
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Old 04-12-2013, 09:41 AM   #75698
FatChance
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Quote:
Originally Posted by mattomachu View Post
Just bought a 2003 DR650 It has 6000 miles on the dial. It wasn't running when I bought it last week. I put a new battery in and it fired up. I don't think the valves have been adjusted since the first owner. This is where the chaos begins. The small cover on the left side with the allen key was stripped into a complete circle. I tried to use a chisel and it wouldn't budge. I ended up taking the entire side cover off. I then drilled the little cover and installed some bolts to to jimmy the thing off.
It is always a good reminder to people to get their bike fully warmed up before trying to remove that plug. When the engine is warm, it comes out easily...
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Old 04-12-2013, 09:46 AM   #75699
ER70S-2
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Quote:
Originally Posted by Emmbeedee View Post
I was looking around for something which would fit nicely in there when I thought I'd give one last try to getting a hose to fit without all that unpleasant carb removal/heating/twisting/swearing/breaking/cursing/searching for another carb which would have been inevitable, considering my luck so far this week...

So I think I'm finally happy with this:

I think the most important part with making this line work is to not have the hose too long. When I first tried it, the bend at the top of the carb connection was quite tight, and it was solely because the hose was too long and needed to make more of a tight curve to go back down towards the Pingel.

The hose I ended up with is probably only 3" long, but it has no tight bends.

Yay!
That looks pretty damn good. And you were able to do it without turning the carb fitting.

Could you put that in Krusty's DR Index? It seems most other solutions are under "Fuel", not "Carb/Intake". (He lists tanks, petcocks and filters in the first post)
http://www.advrider.com/forums/showthread.php?t=635647
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Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 04-12-2013, 10:15 AM   #75700
Emmbeedee
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Quote:
Originally Posted by ER70S-2 View Post
That looks pretty damn good. And you were able to do it without turning the carb fitting.

Could you put that in Krusty's DR Index? It seems most other solutions are under "Fuel", not "Carb/Intake". (He lists tanks, petcocks and filters in the first post)
http://www.advrider.com/forums/showthread.php?t=635647
Be happy to add it...
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Want to know more about the Garmin Montana? See the Wisdom and FAQ Thread.
Want to know more about the Garmin VIRB? See here.
"The motorcycle, being poorly designed for both flight and marine operation, sustained significant external and internal damage," police noted.
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Old 04-12-2013, 10:16 AM   #75701
ER70S-2
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Quote:
Originally Posted by Emmbeedee View Post
Be happy to add it...
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2004 DR650: 62,605 miles
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SUZUKI DR650SE INFORMATION INDEX
Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 04-12-2013, 10:26 AM   #75702
Emmbeedee
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Originally Posted by ER70S-2 View Post
How does this look?
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Want to know more about the Garmin Montana? See the Wisdom and FAQ Thread.
Want to know more about the Garmin VIRB? See here.
"The motorcycle, being poorly designed for both flight and marine operation, sustained significant external and internal damage," police noted.
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Old 04-12-2013, 10:32 AM   #75703
ER70S-2
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That worked so well for you that I'm going to shorten mine (a little at a time), if the weather warms for more than one day inna row. But right now, one day warm spells are for riding, like tomorrow.
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2004 DR650: 62,605 miles
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SUZUKI DR650SE INFORMATION INDEX
Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 04-12-2013, 10:42 AM   #75704
Emmbeedee
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Originally Posted by ER70S-2 View Post


That worked so well for you that I'm going to shorten mine (a little at a time), if the weather warms for more than one day inna row. But right now, one day warm spells are for riding, like tomorrow.
Isn't that what cold days are for? To work on the bike so you can ride on warm days? We don't have heat in the shed but short spells work ok. Then I come back in to warm up by the wood stove.
__________________
Want to know more about the Garmin Montana? See the Wisdom and FAQ Thread.
Want to know more about the Garmin VIRB? See here.
"The motorcycle, being poorly designed for both flight and marine operation, sustained significant external and internal damage," police noted.
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Old 04-12-2013, 10:46 AM   #75705
mattomachu
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Quote:
Originally Posted by FatChance View Post
It is always a good reminder to people to get their bike fully warmed up before trying to remove that plug. When the engine is warm, it comes out easily...
Does anyone know if I take the clutch side cover off if it will be easier to fish that washer out that fell into the left side? I know that the two halves are connected with some oil ports in the bottom of the engine. I can't get a wire/magnet down on the left side w/o removing the magneto. I can't find a puller locally.
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