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Old 08-12-2011, 04:23 PM   #1
EvanADV OP
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Location: Joplor, NC
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DR650 Won't Start - Got Fuel, Got Spark....

2002 with 1900 miles. IMS 4.9 gallon tank, otherwise mechanically stock.

Discovered a leaking base gasket, and decided to use the silicon seal method as a temporary solution.

I removed the tank, cam tensioner, starter, and loosened the oil lines before cleaning and sealing the problem area. Waited 48hrs and then reassembled.

Bike ran fine, and seal seamed to work. I rode it home, then to a customer's house. On my way home from the customers house (~30-35 miles after reassembly) the bike just died. I was at medium throttle in 4th or 5th gear going about 50mph. It felt like i'd just hit the kill switch.

Couldn't get it to even attempt to crank. The motor just spun and spun.

Called for a pickup and got it to the shop. Pulled the wire and used a spare plug to check for spark, which it was getting.

Figured it had to be fuel.

I had removed the filter off the fuel intake line on the carb a few months before because it was giving me issues. I figured for sure I had some trash in the carb, so I took the carb off, completely disassembled it, cleaned it, and reassembled (this time with a filter).

Hopes high, I tried to crank it, but no luck. Still spins but doesn't try to fire.

I sprayed starter fluid in the air box, doesn't do anything. (Just spins)

Took the carb off and sprayed a little starter fluid straight into the intake, nothing.

Hand over the intake while cranking and you can feel suction.

Sand blasted the plugs, confirmed they both get spark, but still nothing.

I'm stumped, and all 3 of the guys at the shop are too.

All three requirements seem to be present - FUEL + AIR + SPARK.

Help please, we're out of ideas.
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Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
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First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner

EvanADV screwed with this post 08-12-2011 at 10:13 PM
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Old 08-12-2011, 07:42 PM   #2
8gv
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Actually there are 4 requirements.....

You need compression. You can use a tester or try covering the spark plug hole with your finger. If there is little to no compression felt with your finger, you likely have some issues. Feeling some with your finger may lead you to a legitimate test with the proper equipment.


Quote:
Originally Posted by c2c4c View Post
2002 with 1900 miles. IMS 4.9 gallon tank, otherwise mechanically stock.

Discovered a leaking base gasket, and decided to use the silicon seal method as a temporary solution.

I removed the tank, cam tensioner, starter, and loosened the oil lines before cleaning and sealing the problem area. Waited 48hrs and then reassembled.

Bike ran fine, and seal seamed to work. I rode it home, then to a customer's house. On my way home from the customers house (~30-35 miles after reassembly) the bike just died. I was at medium throttle in 4th or 5th gear going about 50mph. It felt like i'd just hit the kill switch.

Couldn't get it to even attempt to crank. The motor just spun and spun.

Called for a pickup and got it to the shop. Pulled the wire and used a spare plug to check for spark, which it was getting.

Figured it had to be fuel.

I had removed the filter off the fuel intake line on the carb a few months before because it was giving me issues. I figured for sure I had some trash in the carb, so I took the carb off, completely disassembled it, cleaned it, and reassembled (this time with a filter).

Hopes high, I tried to crank it, but no luck. Still spins but doesn't try to fire.

I sprayed starter fluid in the air box, doesn't do anything. (Just spins)

Took the carb off and sprayed a little starter fluid straight into the intake, nothing.

Hand over the intake while cranking and you can feel suction.

Sand blasted the plugs, confirmed they both get spark, but still nothing.

I'm stumped, and all 3 of the guys at the shop are too.

All three requirements seem to be present - FUEL + AIR + SPARK.

Help please, we're out of ideas.
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Old 08-12-2011, 07:47 PM   #3
Lone Rider
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I'll guess that your trigger coil is shot.

This happened two times on a DR650 I had. Each time was at around 24-24k miles on that coil.
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Old 08-12-2011, 07:52 PM   #4
EvanADV OP
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Quote:
Originally Posted by 8gv View Post
You need compression. You can use a tester or try covering the spark plug hole with your finger. If there is little to no compression felt with your finger, you likely have some issues. Feeling some with your finger may lead you to a legitimate test with the proper equipment.
Thanks for the reply. Didn't think about compression being a necessity too, doh! Guess i'm used to dealing with multi-cylinder engines where it will still run, though very poorly, without good compression on one or many cylinders. I've had an international with a v8 running down the road on just 3 cylinders! This being a single would obviously be a different story.

Intake sucks really hard while trying to start with your hand over where the carb mounts up. Will give it a shot tomorrow with a compression tester.

Still think it should do SOMETHING with starter fluid and spark...we've tried spraying to air box, carb, directly into intake, and even a very small amount into the spark plug hole directly into the cylinder.

If there is low compression, what could have cause that/what could it be?
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Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
9 states left to ride: WI, MN, ND, SD, UT, OK, KS, AK, and HI.
First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner
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Old 08-12-2011, 07:53 PM   #5
EvanADV OP
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Quote:
Originally Posted by Lone Rider View Post
I'll guess that your trigger coil is shot.

This happened two times on a DR650 I had. Each time was at around 24-24k miles on that coil.
Both plugs get spark though. How else do I tell if this is happening?
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Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
9 states left to ride: WI, MN, ND, SD, UT, OK, KS, AK, and HI.
First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner
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Old 08-12-2011, 08:31 PM   #6
RiDR
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I'd eliminate any safety switch issues, kickstand and clutch, then check the kill switch before digging further.
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Old 08-12-2011, 08:49 PM   #7
EvanADV OP
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Quote:
Originally Posted by RiDR View Post
I'd eliminate any safety switch issues, kickstand and clutch, then check the kill switch before digging further.
Wouldn't all that stuff prevent the engine from turning over?
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Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
9 states left to ride: WI, MN, ND, SD, UT, OK, KS, AK, and HI.
First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner
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Old 08-12-2011, 10:30 PM   #8
RiDR
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Quote:
Originally Posted by c2c4c View Post
Wouldn't all that stuff prevent the engine from turning over?
I think Kill switch and clutch yes, not sure about the kickstand switch.
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Old 08-12-2011, 10:49 PM   #9
EvanADV OP
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Quote:
Originally Posted by RiDR View Post
I think Kill switch and clutch yes, not sure about the kickstand switch.
Will double check them all, but if i'm getting spark i don't understand how they prevent the engine from starting.
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Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
9 states left to ride: WI, MN, ND, SD, UT, OK, KS, AK, and HI.
First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner
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Old 08-12-2011, 10:59 PM   #10
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Really wierd, you have messed with the cam chain tensioner,,,,,
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Old 08-12-2011, 11:03 PM   #11
RiDR
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Quote:
Originally Posted by c2c4c View Post
Will double check them all, but if i'm getting spark i don't understand how they prevent the engine from starting.
Just did a search, the kickstand switch will completely disable so you are correct, missed that your engine was trying to crank over, apologies... if you have an aftermarket tank without a vacuum petcock you might have had to kink off the breather hose out of the carb, grasping at strings but maybe another thing to check. Good luck.
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Old 08-12-2011, 11:05 PM   #12
EvanADV OP
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Quote:
Originally Posted by bluebye View Post
Really wierd, you have messed with the cam chain tensioner,,,,,
Yep - had to take it off to get the starter out. Put it in just as it came out AFAIK.

Weird thing is it didn't chug down like it was a fuel prob, just died at 50mph instantly like i hit the kill switch. That seems like it be ignition, but i have spark.

Yikes.
__________________
Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
9 states left to ride: WI, MN, ND, SD, UT, OK, KS, AK, and HI.
First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner
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Old 08-12-2011, 11:09 PM   #13
EvanADV OP
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Quote:
Originally Posted by RiDR View Post
Just did a search, the kickstand switch will completely disable so you are correct, missed that your engine was trying to crank over, apologies... if you have an aftermarket tank without a vacuum petcock you might have had to kink off the breather hose out of the carb, grasping at strings but maybe another thing to check. Good luck.
No worries, it was a long OP

No vacuum petcock but i capped the original vacuum fitting on top of the carb. Cap came in IMS kit.

I've tried starting fluid...so even if it was a fuel issue it should bump in theory. Doesn't seem to do anything.
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Current Steeds: '08 FJR1300 | '02 DR650
Former Steeds: '99 DR650 | '02 DR650 | '09 DL650 | '07 B1250
9 states left to ride: WI, MN, ND, SD, UT, OK, KS, AK, and HI.
First Trip on 2 Wheels. 10,000 miles. 21 years old.
NC to Maine for Lobster Dinner
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Old 08-12-2011, 11:10 PM   #14
knybanjo
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Take the tank back off and look for any loose connections and/or pinched/chafed wires. Then test all your coils per the manual. Besides the main spark coil you also have the magneto igniter and the pick-up coils. (I think the pick-up may also be called the trigger)



Quote:
Originally Posted by bluebye View Post
Really wierd, you have messed with the cam chain tensioner,,,,,


Yeah...you may be onto something there..... You should probably take the valve cover off and double check the cam chain and timing too.
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Old 08-12-2011, 11:23 PM   #15
knybanjo
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Quote:
Originally Posted by Lone Rider View Post
I'll guess that your trigger coil is shot.

This happened two times on a DR650 I had. Each time was at around 24-24k miles on that coil.
Is this the coil that tells the ignition when to spark? (sometimes called a pick-up coil on other bikes)

That could very well be the problem, you have spark but it's out of time?
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