Master Mechanic Gave Up On This 650cc Street Legal Dirt Bike

I buy a 1995 Suzuki DR650 street legal dirt bike and attempt to fix it. #Suzuki, #650cc,
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The following video features activities performed in controlled environments by knowledgeable persons. DO NOT attempt to duplicate, re-create, or perform the same or similar activities at home, as personal injury or property damage may result. 2vintage( Joe Weber, the persons shown in this video and ANY CONTRIBUTOR, ARE NOT LIABLE FOR ANY such injury or damage. ALL 2vintage( Joe Weber) CONTENT IS FOR ENTERTAINMENT PURPOSES ONLY.
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[@fboomerang]

THIS WAS MY BIKE FROM 2014 to 2019! IT WAS AWESOME!! I wish I kept it. So much quality time in Death Valley on this machine!

[@volvogt21]

A bush pig!! I have one and still ride it weekly. It has been round Australia about 3 times. Legendary bike. I agree. The carb

[@oslo4251]

I want one so bad, just checked the 2023 model brand new around 7000 euros,

[@rick5619]

I like it when you include the adventure of going to look at and bringing the machine home added to your video Anyone else?

[@jerrywilcox9890]

You get what you get so quit complaining.

[@jerrywilcox9890]

@Jake Demuss it's called complaining lol no matter how ya want to put it.

[@jamessvaren1716]

I would check for exhaust restriction and also do a careful inspection of the intake manifold. It is after all 28 year old rubber. Good luck

[@jamesstewart3785]

I was thinking the same thing.

[@cesarbaptista4470]

I came here to say this

[@marksaround]

That's the same thing I was thinking

[@blackkoi-pd4eo]

That’s exactly what I thought also. I never saw anything smoke wise come out of tail pipe

[@hearttraveler1548]

GREAT VIDEO, THANK YOU AM THINKING SAME, I HAD A KTM 620 RCX THAT BEHAVED SIMILARLY..... THE MUFFLER INTERNALS HAD COLLAPSED MOSTLY PLUGGING FLOW

[@Mrcrawford100]

After the Vinnie dance, I was like ok, now I see why Vinnie doesn't like him 🤣🤣✌

[@clarkvantussenbrook6536]

I had a Raptor 660 that acted like this. I chased the issue for a long time. It turned out to be a sheared woodruff key on the flywheel. Timing was mechanically spot on but the flywheel had rotated and so it was firing when the intake valves were open, which could explain the smoke coming out the intake. The other thing, these vacuum slide carbs are a real pain. Very sensitive to air/fuel mix. With the lack of adjustment on the needle you have to play around with the mixture. It could be that its dumping way too much fuel when you roll on the throttle.

[@joshualynn6994]

I definitely think it’s a timing issue being it’s blowing out of the air box

[@wesboos9174]

This is good thinking. Especially with a high compression engine like this the wood drift key in the fly wheel could break for any given reason.

[@taylor_imaging]

@@joshualynn6994 Too lean will do that too

[@Crosshatch1212]

It’s spark wastage .look at boot on plug .when checking for spark ,it’s leaking spark .

[@steventhoene]

Check for blockage in the exhaust.

[@jeepurz57]

kina what im thinking.

[@jaymcnaughton8368]

I was noticing to that no smoke out of the exhaust even though he put oil in the cylinder.

[@rvmonkey1669]

I agree

[@simenthorvaldsen]

That is just to funny, I picked up a 1992 DR650 yesterday. 👍

[@lastoppertunity333]

And I must say that dog is fast as shit too lol. U could see how quick he is in the video u were riding the yfz in ur backyard after u got it done.

[@KOedNAC]

I should've never sold mine. So easy to work on. This bike helped me learn how to work on all my bikes. When you saw the carb was broken, I remembered how it was the only junky part on my dr. Great video

[@ographicshd3467]

The air filter will be the issue! I had the exact same issue, you need the filter in place for the slide to be able to move up and down other wise when you throttle it won't have enough vacuum/pull to move the slide👌🏼

[@jerrywilcox9890]

Mine runs just fine with no air filter hasn't had one for 2 years.

[@M.TTT.]

@@jerrywilcox9890 that's not good lol

[@MrATOMBOMB420]

It doesn't matter whether you have an air filter on it or not

[@MrATOMBOMB420]

The same amount of air comes through whether it's on or off the difference being whether the air box lid is on or off but the slide will still move the same

[@M.TTT.]

@@MrATOMBOMB420 a filter is to an engine as a resistor is on electronics, is it not? Seems so, common sense wise

[@74charger44]

Joe, I have to say thanks for your videos. I came across a portable generator that a guy wanted to trash it. No spark. I took it home , no spark. I remembered the video when you pulled the plug boot off and found no wire. You cut it back to good wire, reinstalled the boot and got spark. Same with this generator. 4 pulls and it runs . Thanks Joe.

[@2vintage]

Awesome!

[@davidhackney6536]

Doublecheck the intake manifold for cracks. Hard to see when on the bike. Keep up the great videos!

[@ronhanish]

spray starting fluid on manifold, increased rpms will reveal

[@jayeddleston9486]

Heat gun on carb intake boot softs the rubber up easier to get out

[@mircearadu3854]

I have the 93 with only kickstart, killer bike, just love IT. You need to tighted the balancier chain on it, put a 150 main jet and it will be a wheelie machine

[@onebigchevy16]

You might want to take a look at the cam journal on the cylinder head again. It sure looked like the cam had ate into it quite a bit. It would explain the super loose rocker arms/valve adjustment

[@G31mR]

Yep. Good eye, there.

[@Poksutin]

saw the same

[@garysgarage3669]

That gas tank in huge.

[@ronaldnajarian7506]

The dancing was a riot

[@shawnstjohn3831]

Check your tail pipe. Lots of smoke out the carb, not a puff out the pipe. Sat outside for a while. Could have nest, trash, etc clogging it up. 🤷🏼‍♂️

[@zane762]

Most people love em or hate em , pos oem carb , and constant need of valve adjustment.. but once it's cranked it'll literally fly.. good luck 👍

[@dominicharvey9680]

Exhaust is the most probable cause. That’s why it was smoking back through the carb. Exhaust can’t expel the air quick enough when you try to rev the bike

[@jamesdriscall3237]

I have 2 of these bikes. One to ride and one for parts. This vintage (1991-1995) DR650 share almost no parts with the 1996 to present models. The BTS carb is known to be problematic, especially off idle. I ditched mine for a 40mm pumper carb. It flows and responds much better at low engine speeds.

[@M.TTT.]

So would you say 96 and on are better overall?

[@jamesdriscall3237]

@@M.TTT. not at all. Just pointing out, other than the name, the two models share nothing in common.

[@Michael-to7oz]

Did anyone else notice the metal shavings around the cam journal when he was checking the timing ? That looks chewed up real bad !

[@besenwieslersepp1011]

looks like the camshaft "bearing" on the chain side is totally gone! The cams seem to be worn out as well. I know such problems from the DR 750/800. They need 1350 +- 150 idle speed. If they run too long too low on the sidestand, the whole cylinderhead-/rockerboxassambly is gone due poor/no oil supply.

[@Michael-to7oz]

@@besenwieslersepp1011 It definitely has a strong bottom end but it's gonna need a new cylinder head for sure.

[@besenwieslersepp1011]

@@Michael-to7oz sadly the cylinderhead and the rockerbox have to be changed together as a unit. Because they are bored and reamed together.

[@billlloyd9142]

Looks like the end of the cam has alot of shavings under it, looks like it might have been run low on oil. As for as it reving up i would put a good battery on it.

[@stanleydunne3498]

Cam bearing looks knackered, on the side you were showing the timing marks.

[@baybuoy3843]

☝☝☝This !!! ☝☝☝

[@brianmarsh4498]

When you were checking for a spark earlier the spark was shorting out from the rubber that surrounds plug onto cylinder head so you had two sparks, you missed that.

[@dannygilbert9477]

I saw that to

[@slowburn_1725]

I owned a 02 DR 650 dual for 6months and it had to go, unless you gear them different or do sprockets they are slow turds and with a full tank of gas they are really top heavy on the trail, good luck

[@johnthorstad4048]

When you had the cam cover off to check timing, the cam journal looked cooked.

[@briancrull8678]

cdi box or the pick up is failing Common on old big thumpers Hondas do it all the time Seeing that puff out air box says a lot

[@Gasgaspro]

I did not see one puff of smoke out of the exhaust! Maybe plugged ?

[@eugenesbackyardrepair4593]

I bet there's 10 of us saying why no exhaust smoke at all

[@KelleyCycle]

35min in Joe, that top end is history dude....drive side cam journal torn up as is the ally bearing surface (likely the valve cover too). Take a close look at the rocker pads for wear marks too. You're gonna need to dig into this one :(

[@randalblack6361]

Hi, I noticed that when you first checked for spark, besides the spark at the electrode, you were leaking a massive amount of spark from around the top of the boot to the head fins. May be a factor as spark voltage increases as you Rev on some systems, causing a worse shorting problem as voltage increases.

[@blackkoi-pd4eo]

I saw the exact same thing

[@neiljarvis8911]

Saw it too!

[@Crosshatch1212]

Well off course it’s gonna cause it headaches and yes spark increases with spread ,more fuel more sparks .think spm

[@dennis82468]

You need to take that bike for the Idaho Backcountry Discovery Route. It's an adventure ride :)

[@thebigguy8306]

I am surprised Joe has not been invited to one of those weekend gigs, Polaris Ranger at Black Bear Pass, or Can-Am RZR in Moab UT

[@nodaklojack]

I rode an xt 600 from San Diego to North Dakota. Iron ass.

[@bigjohnson7415]

Indeed! Much respect, my friend!

[@kevinsimpson7687]

I would upgrade the carb to a flatslide carb. Mikuni TM40 or an FCR. That'll wake it up lol.

[@oslo4251]

Just the acerbis 25 litre fuel tank by itself cost around 400 euros !

[@njb7209]

Check the wiring harness by the light support bracket on the right side of the steering head. The metal can be sharp and cut the wire insulation.

[@2vintage]

I will check that

[@craigb471]

Noticed little or no smoke from exhaust it could be it's blocked rodents nest and choking engine hence carb smoking

[@bbroken1]

Start it with exhaust off see it runs

[@jeremymullen5378]

🔥remove that muffler/silencer I’ve seen them plug up over years of ppl putting around. Fire it up with just header🔥👊🔥🔨🏍⚙️

[@johnbest4320]

Really fun bikes these Joe nice pick up bud if it isn't the carb & the air filter only thing I could think of is exhaust definitely worth a look after you get the carb & airfilter the bike is in really nice condition once running you should have a load of fun really nice machines to ride have a nice week mate look forward to you getting it running great content #2Vintage 👊💨

[@thebigguy8306]

Love the channel, always a learning moment, good looking bike. I owned a 96 RF650 and thought it was a great bike

[@rangerddanger697]

Looks like it has a after market fuel tank, acerbis fuel tank cost almost as much as you paid for the bike 👍 You got a great deal there's so many after market parts for those bike , 👍

[@jonnyonwheels]

I would double check to see if it’s the right cdi and check the pickup.

[@GhostHuntersFriesland]

Vinnie is eating the yellow snow! 😂

[@jaredmcquiniff5362]

I have a 97 DR 200 and when I bought it, I had to pull the carb off and clean it. I ended up breaking the intake boot which was already rotting. Anyways, I chose to plug the vacuum lines and run a manual petcock for a Kodiak 450. It ran so much better without the vacuum fueling! Great video as always, keep it up Joe!

[@shartne]

Air filter is a must. MANY times its the lack of a air filter.

[@troyrosenbaugh9935]

Love the DRs. Had a 92, rode the hell out of it even a trip from Southern California to southwest Colorado. Ass was sore but that bike is fun, tons of power, smooth as silk, super fast. Will bite you if you aren't ready for it.

[@danelldecker3696]

Check the exhaust a engine can only take in as much air as it can blow out. If the pipe is blocked (critters) it could easily blow back through the carb.

[@alexgroezinger762]

Should try and get your hands on Drz 400

[@97delkron]

was thinking the whole time it needs the filter. glad to see you with a dr650. i been riding dual sports for many years and have had many different models. the dr650 is bout the best one made. good score for $800.

[@michaelzuccaro1798]

I have a 1991 dr350.broken tube on carb like you.switched to a new pumper carb.bike runs perfect now.thanks for the great videos.

[@eugenesbackyardrepair4593]

Good u got the 650 electric start. My son has the 350 kick start only and it's a pain to start. If you know the exact procedure to start them he says it not hard but if you don't takes too many kicks to start. He does love it because it's an on/off road.

[@christaylor2168]

If the new carb doesn’t fix it. I’d check the woodruff key in the flywheel.

[@askfadzean]

Vinn is always insulting your bikes xD

[@CurtPottorff]

Just a word of caution: Pre-1996 DR650's are VERY different bikes than post-1996 DR's. Pre-96' bikes are very difficult to source parts for, there is not nearly as much aftermarket support for them. Check the chain-driven balancing system religiously, as it will grenade the motor. I believe the factory service says every ~2000 miles or so it should be checked/adjusted. Also, the bike may not run without an air filter. The carb actually needs the filter in to run properly. The biggest thing with the earlier DR's is that parts are difficult to source. They are great bikes, but just simply no where near as good as the 96' and later models, and often leave the owners getting rid of them for cheap because parts are nearly impossible to source.

[@LewisMowersandBoats]

Go with what you think. got to have that mix right and back pressure . Great show brother 👏

[@76vetten]

I’m new to your channel. Wonderful. I’m really enjoying your trouble shooting. I had a problem on a Yamaha 426. Just couldn’t get it to run right. A guy suggested I replace the needle itself. It looked perfect. I did and that was it. That was a new one on me. Great video. Thanks…

[@gregorygrubb6126]

It is the carb I've been a suzuki guy all my life these DRS have carb issues .great video your awesome!!

[@davidgoodwin958]

You know your stuff, and you are darn good at it!

[@mattbillings2032]

Excellent dismount unloading the bike. I bet @MichaelSabo couldn't do that! 🤣🤣

[@tyee4u]

Finally you’re working on my bike 😂 I have an 04. On mine the fuel/air screw has a washer and a small O ring on top of the spring. When I bought it, it was missing and ran like crap. Once I sorted that it runs like a top.

[@RATADATUAVELHA]

yes I did noticed that also, it is missing. I think the o-ring is crucial.

[@jamessvaren1716]

I had the same thought. Should be an O ring to seal the screw

[@b.t.bohler9734]

Often the little o-ring gets stuck inside the carburator - check for that first..😉

[@princes9577]

maybe you could test using something to restrain fuel flow in that line...vise-grips or an old fuel petcock might do the trick...before ordering a new carb...good job mate i really enjoy watching you working !

[@troyrosenbaugh9935]

That compression reading is good! Still like new, it's gonna scream.blowing back through carb by the intake valves. The valves on them are kind of a pain to set especially the exhaust.

[@jamesbeckwith780]

Check for plugged muffler.

[@dougmpage]

Those side panels & front light are just begging for decals once they are cleaned up! Definitely a nice grab!

[@dopeman420]

I agree 👍

[@rvmonkey1669]

If you suspect a fueling issue while at part throttle spray a little brake clean into the air cleaner to see if rpm picks up. If you suspect loss of spark use a timing light on the spark plug wire if you lose flash off idle you’re losing spark.Good love class always enjoy your videos!

[@maxwellsmart6601]

If a Master Mechanic touched this bike, YOU wouldn't have to turn a wrench on it. Comical title.

[@staygold902]

It's the air filter. I've never had a cv carb work properly without one

[@AndrewReid-wb9ih]

i woukd make sure the exhaust pipe is clear if it pops back through the carb idleing,,,,, great channel bloke👍

[@kernelbadness]

For this reason, Always take the extra time to remove your carb properly even if it means to remove your airbox. Now you have a broken carb and possible a crack in your intake boot. 😢 10 extra min.

[@seedsman02]

Hi there, Kevin from Australia here. I really enjoy your show, what you do and your presentation is real and honest. And the way you talk to yourself at times hehe, and how you deal with disappointment. I have to ask where do you live, because sometimes i open your show and there is literally feet of snow outside, and to me that is always a shock lol

[@upsdoug]

An old friend had a Suzuki DR 350. The previous owner had taken it to several dealerships and other mechanics and couldn’t get it to run correctly. My friend spent hours and hours and put quite a bit of money into that bike but it never ran right. We all conspired to burn it in the desert and then surprise him with a comparable bike that would actually run😄

[@steammartian7705]

I’m going through the same thing with my Mojave. I’ve replaced all the electronics even though I knew they were good. But I’m starting to believe that it maybe an issue in the case. Runs good. Starts up. But very same issue. Starts right up. But u can’t press the gas. It has to run for like 15 mins before u can be able to ride. But when your riding it rough and let off the gas it dies. But first kick turns right back on. Idk 🤷‍♂️

[@douglasfitzsimmons654]

Hi Joe love the content, when you were doing your spark test on the big DR it looked like there was spark jumping fro the plug cap (boot) to the head, possibly cracked spark plug cap. Hope the helps. Keep up the good work.

[@6226superhurricane]

i saw that too but it was a spider silk when the bike was cranking the plug was moving and light was shining on the silk making it look like a spark.

[@antofagastaride]

I had a dr 350 that worked like this ..once my kid noticed a spark coming from the spark plug boot to the head ..change tje boot and the problem was solved. I also saw the fugitive spark when the first sparkplug was tested

[@stevenmasters9574]

Made the same assumptions as you did on a xr250 in Thailand. Spent about 3 weeks working on it. As a mechanic I failed to use the KISS meathod and wasted time and money. Go back to the original problem, CDI. I was sold a wrong CDI several times. Finally went to a running bike and took the CDI unit. Simple fix. The wrong CDI units started the bike just fine and had a stong spark but would not accelerate. This lead me down the same path you took. I assumed because it started so good it must not be the CDI unit. I did everything you did also just to have it do the same thing every time. Hope this helps. Love your channel.

[@AZVIDS]

Cool bike, cannot wait for part 2👍👍👍

[@Stephen033]

There is a way to get into those analog odometers. I had an old 91 gmc that I replaced the gauge cluster and the odometer was analog and I was able to turn it back and set it to the actual miles the truck had

[@barbaraneville5036]

Back pressure in the blocked exhaust pipe ?? One thing you haven't checked for is a mouse nest in it

[@neiljarvis8911]

Lean on idle jet, need to richen to compensate for ethanol in fuel. Possibly low low level in float bowl too. Dont need new carb - fault diagnose what you have for cheap. Can add bigger main jet and raise needle once richened on pilot system first. Thoe plug caps go hi resistance too, but you have a good spark at the moment. Good luck!

[@papasmurf159]

You did well getting it up your car ramp, hard enough getting it down. Fun video.

[@TapzVSWorld]

i cant belive your not at 1m subs yet youve got a very knowledgable channell i llove it

[@SaMnoaJaFa]

Hehe nice, finally video for the Suzuki DR’s. Please make a video regarding the DR 350. They are legendary for their durability and ease of use just like the XR/TRX

[@sethfricke616]

You need to find a xr650l next. Those are a beast of a bike.

[@GratefulEd907]

He only buys non running bikes. All the honda Xr650Ls still run great. LOL

[@bananabrooks3836]

​@@GratefulEd907Honda owners are like Stepford wives.

[@GratefulEd907]

@@bananabrooks3836 I’ve seen that movie and honestly think the Stepford wives were way better than an actual wife. So thank you

[@bananabrooks3836]

@@GratefulEd907 😁😁Haha, good defence.

[@johnlangston466]

I had the same problem with my DR650 ordered a DYNOJET KIT for the carb fixed the problem instantly

[@MrBobele]

Hi. I had the same issues on my dr 350 with the Carb. On the BST Carb there is a vacuum connection point for the original petcock. With the Acerbis petcocks you have to close this connection on the Carb. After closing that the dr runs fine.

[@ukaszmak1663]

Check the CDI coil. Measure the resistance of this coil. The values ​​should be listed in the manual. Greetings from Poland

[@MakinEndsMeet69]

Hey Joe I think the guy from low-buck garage has one of those bike as well not sure if it's a 650 or not but it sure does look identical. I forgot he had some issues with his as well but for 800 bucks that's a good deal. That is definitely one hell of an Enduro.

[@greathornedowl3644]

Love the channel, ARGH - hate carb problems. Nice bike, quick turnaround? Joe tested, 🐕Vinny approved

[@davidsymonds8185]

Hi Joe when you testing for spark saw the plug cap were asking through the rubber cap

[@thoringuidry]

I don't know close to what you know...the only thing I would have tried in this situation would be shorten the makeshift line you replaced the broken tube with...might be too long of a distance to travel with the increased diameter of the hose...and maybe increase the idle screw a bit, other than that I'm stumped. Good job on all you do bud!

[@Unknownas1337]

Bulletproof bikes. Have 95' myself. Love the bike!

[@jameskrause8902]

Well, they can't be that bulletproof if Joe has one in his garage.

[@besenwieslersepp1011]

The broken tube is the choke-tube. With uncorrect flow in that tube and without aircleaner, it can be difficult to start the engine at low temp. I also missed the o-ring and the tiny washer on the idle-mixture screw (may be you dont f.ilm the "extraction"). If it runs, look at the manual for the correct idle-speed. Those singles are notorious for killing their camshafts and rockers at too low idle-speed on the sidestand due to poor oil supply in the cylinder head.

[@davidfalgout7304]

Besen.... is this true of the models after 2016? I do not think so? What do you think? There are tens of thousands with well over 40,000 miles and no problems.

[@besenwieslersepp1011]

@@davidfalgout7304 I have a 1997 DR 800. It runs perfect with 70.000 km on the clock. But if I let it run for 5 minutes on the side stand with the idle gas too low, the cylinder head would be scrap. There is a reason why the manual says: 1350 rpm +- 150. I have n idea of the newer Models.

[@davidfalgout7304]

@@besenwieslersepp1011 I would think that a 20+ year difference in engine design would mean the 2016 and later 650 engine would not suffer from that..... what do you think?

[@besenwieslersepp1011]

@@davidfalgout7304 I can't judge that, but it is to be expected that improvements will have been made in 20 years.

[@mikehudg2209]

I love it !!! Awesome bike !! I have a xr650l I ride everywhere in the summer !!!! Great video you will love this torque monster 👹

[@peteraitken6494]

Nice bike joe yeah got to be a carb problem and possibly filter don’t really know much about these bikes but you will figure it out for sure vinny thought it was crap lol💩💩💩👍👌🔧🔧🔧

[@jamestefft314]

Hard to tell what it really sounds like from the video and didn't see anything shoot out of the muffler but maybe try disconnecting the muffler and run just the header pipe to see if it's clogged. With you saying it sat outside, something my have gotten in it to clog it and could be the reason it won't rev out, might not be able to breathe.

[@brianwhalen5909]

Jaysus. That's a FUBAR'd cam journal in the head at 34:46. Look at the aluminum that's galled up and spilling out the side. I doubt that head will live much longer without wiping out the cam with it. when it seizes up. Find out what's causing that! Lack of oil pressure to the cam? Debris in oil passage? Or low oil level and run dry by the PO maybe.

[@snowyowl7042]

Good looking cycle, quick cheap fix 🤔 Good for you.

[@faf4913]

Hi, if it helps, I have a 93 model DR 650 R with kickstarter, it's a wonderful bike. If you have to change the carburetor I recommend the Mikuni CVK40 that will probably solve the problems that appear in the video.

[@mitchellthompson1534]

You need to actually hook up a battery to the terminals for the CDI box to maintain power for it to the coils it’s a safety mechanism as soon as you touch the throttle it will die complete the circuit with an actual battery then put jumpers on

[@fredbaxter481]

Maybe vacuum problem! That slide is operated by vacuum. Just a thought. Love your channel buddy.

[@kennethnonya3652]

Maybe try pulling the baffle out of the exhaust?