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Old 01-01-2008, 12:51 PM   #1
vegpwrd OP
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Joined: Dec 2007
Location: The Big Sleazy
Oddometer: 165
Question 03 DR650 Carburetor Rebuild

Hello All,

I'm new to the forum although I've been shuffling around it a bit for the past month+. I just purchased an '03 DR650 w/5K.

The previous owner did a good job at F*#@!G up the carburetor somehow. I did a group of thread searches on this topic in this sight before i posed this question: I need a guide for maintaining, overhauling/rebuilding DR carb. I'm also having a hell of a time finding any general maintainance guide books on the bike (the previous owner did not have any). I am very mechanically inclined although my lack of experience with this bike is prohibitive. I prefer books to CD's even if I have to pay a little more.

Any suggestions or references are welcomed and appreciated.

Thank you,

Ross
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Old 01-01-2008, 02:21 PM   #2
bumpathump
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Oddometer: 327
Ross -

Congrats on the new bike.

Service manual is online at http://www.deakin.edu.au/individuals..._adm/DR650.pdf

Pilot jet is sensitive to old gas. Clean that out first, drill out the plug over the pilot screw and rotate the screw ccw 2-3 turns for richer lowend mixture, check the main jet for oem or larger size, check the needle for oem or DJ, check the airbox for removed side panel or holes drilled.

Lots of info on mods on this forum and the DR650 yahoo groupl.

Good luck. Have fun.

Rick
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Old 01-01-2008, 03:59 PM   #3
vegpwrd OP
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Wow! Thanks for the repair manual download!!!

. . .when i check the main jet and the needle, do I refer to manufacturer or DJ specifications for settings?

Thanks again - R
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Old 01-01-2008, 05:39 PM   #4
Marvin_ADV
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Location: Norfolk, VA
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Hopefully your carb isn't too bad off may just need a good cleaning, esp. pilot circuit. Sounds like the bike sat awhile.

You can find an exploded parts diagram of your carb at RonAyers.com

Here ya go:
http://www.ronayers.com/fiche/300_03...00&parent=1170

Good luck!
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Old 01-02-2008, 09:03 AM   #5
bumpathump
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Ross -

> when i check the main jet and the needle, do I refer to
> manufacturer or DJ specifications for settings?

If the needle has one groove for the clip, it is an oem needle. If it has more than one groove, it is a DJ or other aftermarket needle. OEM main jet size is listed in the service manual. If the number on your main jet does not match the number in the manual, you have a different main jet - either larger oem or DJ or aftermarket main jet. Once you determine what you have, you can decide which way you want to go.

Rick
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