Suzuki DR650 Overhaul Timelapse

After finding a lot of iron filings on the magnetic drain plug, it was high time for a bit of an investigation.
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/ oztoice

[@karlroberts1827]

Looks dead simple! Next time I have 13 minutes and a bucket of methamphetamines I will do a rebuild! Seriously, I found your video very educational. Now I know what my DR's guts looks like.

[@brohamma]

🤣

[@brohamma]

truly effing amazing. the knowledge, patience, motivation, skill...so insane. literally might b slightly insane/on spectrum. i about shit my pants when fourth gear almost didn’t work on second go.

[@codedirtytome7178]

For all those asking for a slower version, just click on the little gear (settings menu) in the bottom right corner of the screen and then change the playback speed to 0.25

[@eduline]

WoW! What a wonderful thing to watch. This is a masterclass. Thank you!

[@paularcaria]

3rd gear usually exploded on the DR. Good thing it gave u a heads up first.

[@dassingeratgmail]

Great very informative with best-practices professional mechanical procedure and technique. Thanks! Gives greater insight into the engine and entire Suzuki DR650 and the skill-set of a professional/master mechanic.

[@huskychronicles3249]

Thank you. I'll be taking my engine apart this winter as I have found a piece of a snap ring in my oil, so this video is very helpful and gives me a little bit more confidence attempting such a task.

[@bm7760]

Did it last until winter?

[@huskychronicles3249]

@@bm7760 I rode it like that for about 15k miles before I addressed it. YMMV

[@hailwood900]

This is the best 'non-video' I've ever seen. It must have been a crap load of work to shoot and edit all that. Thumbs up on the comment about Amsoil Dirt 10/40. We've used it for years in our off road race bike and I will swear it adds to the longevity of a motor. Great rebuild. You sir are welcome to work on my bikes any time. I'm about to buy a DR, and if I watch this a couple more times, I'll be ready to do a rebuild, should the need arise. Finally someone that operates at the speed all shops should work at! LOL from Green Bay, WI.

[@johnrogers5825]

I'll be bringing my bike in to you, as I feel because you work so fast, that your hourly rate should work out cheap for me.

[@MrMacacoMau]

Really nice video and awsome work man! Respect! I will eventually do the same to my DR, great inspiration! peace

[@extremeenduro1560]

Rob, I am jealous of your skill. I couldn't get that back together with a gun to my head. Nice work.

[@pijuskr2886]

great great video. and using cardboard for bolts is a great idea. I only wish the video was normal speed, I'd watch it like the best film ever. thanks Rob!

[@justgjt]

You work fast and must know a ton of stuff. Respect !

[@jedzeppelin221]

Have to tear my trusty old DR down and swap motor cases (98-99 with no torque limiter, broke off motor boss), will consider this video a resource, big thanx, subscribed.

[@donovanlucibello379]

This video makes me happy just watching it - nice work!

[@nickstroke]

I'm in the middle of doing the same thing on my engine, however I'm having trouble when reinstalling the gears (transmission). I noticed @4:32, you had to remove yours multiple times before proceeding. When I have mine installed, the topmost gears do not sit flush next to one another, as if the shaft needs to be pressed in 1/4" more. Is this what you went through too or was it something else?

[@GladiusJon]

You are a very skilled technician!. Nice video man!

[@billhamilton2366]

I never use silicone to assemble parts. I use gasket shellac on one side and grease on the other side of the gasket. When there is no gasket I use gasket shellac and a piece of polyester thread laid into the wet shellac then let it set up for about 5 minutes before mating the two parts and I use shellac sparingly on both halves. I never have issues. and the parts come apart very easily if need arises the next time.

[@ronenfe]

If you upload the normal speed video it would be helpful to many people.

[@ferdinandreinhardfr]

Yeah you so right!!!

[@ericcournoyer1595]

Music to my eyes.

[@KD-hb8zi]

That's one of the coolest things I've ever seen.

[@Uts9000]

that is a knowledgeable mechanic, i hope you tipped him

[@robarmstrong930]

thanks, that was me haha

[@CowboyJimRob]

how much does a job like this cost the customer?

[@robarmstrong930]

im not sure. ive never charged anyone for it. only rebuilt my own motor

[@nedt]

thank you good insight into doing a rebuild

[@steelmilkjug]

Ah, yes, the 3rd gear issue. Just curious... how many miles and what year was this bike before you noticed the shavings? Also, what was the total hours spent on this fix? In other words, what would the mechanic bill be for something like this? Thanks! I'm looking at buying my first DR650.

[@kingmatthews5436]

Nice video and I hear a thing every now and then on the video like it was going to play a song lol

[@kingmatthews5436]

And was a lot of parts really tight and hard to get lose on your bike?

[@nathalierojasjimenez6475]

Excelente vídeo. Que maravilla

[@germanbernal8655]

Really enjoy the video, i'm doing a XF650 rebuild wich have the same bottom end, and i also have that sexy tan color inside the cases, my engine shows signs of overheating, so i'm thinking this is a layer of burnt oil, but don't know for sure, is a good idea to remove this layer? maybe that coat makes the engine run hotter? If that's the case maybe you should take a look at the head because i have a cracked head that only became visible after decarbonize, Thanks

[@naym0001]

This is a fantastic video... few quick questions - 1. do you know if anyone makes a bottom end rebuild kit? 2. if you replace the bottom rod bearing, does that require basically a new crank shaft assembly? Thanks!

[@Jolly-Josh]

I’ve rebuilt two DR engines, I’ve not heard of any kits available. All of the bearings except one are easily obtainable through a bearing supplier, one bearing must be obtained through Suzuki. You have two options for the gears, either Suzuki or Nova Racing. The bottom end bearing can be replaced however you will then need to have the crankshaft re-aligned..best to pay someone to do it if your not familiar and don’t have the correct tools.

[@andyblack5687]

Sir you seem to be very knowledgeable about the DR650 engine. Maybe you can give me some advice. At 10,000 miles (16,000 km) my engine started getting much louder than it had been. It's not a ticking or a knocking sound; it's just way louder than normal. I adjusted the valves, changed the oil, etc. with no change. I didn't find any iron filings but there were some shiny, gold colored specs, possibly brass, in the oil. This was about the time I started smelling the clutch burning too, so I put in all new friction plates, thinking this would solve the noise issue. The burning smell stopped but the noise remained. I listened to the engine with a stethoscope and the noise seems the loudest on the fly wheel side of the cases. I haven't taken that cover off yet. Any idea what could be causing this noise? It's not a chain tap sound or a piston slap sound. It's almost like a chugging sound. Thank you.

[@brymanable]

but what was the cause of 3rd gear to grind tho ?🤔

[@tomosan1967]

Getting the same amount of metal on my magnetic drain plug also, even found a small chip that looks like the edge of a gear. Was wondering if it might be third gear, you vid has pretty well confirmed it.

[@jaybourbon8608]

Hey what year and what milage was on this bike? Did you notice any whining in 3rd gear? I just picked up an 07 and I have 3rd gear whining. Suzuki supposedly corrected the issues with the gears after 06.. I am finding after coming across many posts that they obviously did not correct the issue. How did the bike shift before the rebuild? I have 11k miles and it runs great but there is the 3rd gear while..How concerned should I be?

[@robarmstrong930]

Milage since the last rebuild was about 60 000km. but dont take that as a good example. this engine had another problem from a previous rebuild due to 5th exploding. Bike shifted fine before this rebuild and the 5th gear incident. there was no whining with this one but there was before 5th gear went. suzuki changed part numbers but the failures have continued. id say just be careful with all the online "expert" opinions. 11 000 miles sounds low for a failure. my 5th gear went at about 42 000 miles

[@jaybourbon8608]

@@robarmstrong930Thanks for the detailed response. I think the safest thing to do is get a good magnetic drain plug and I'm going to run Amsoil Dirt synthetic 10w40. I have yet to drain the oil but I will assess the damage, and see if there are shavings or chunks of gear in the oil. Found a video of another 07 with 15k miles the 3rd and 5th eaten away.. So yeah Suzuki changed the gear in 06 and then again in 08 so I'm thinking they tried another gear that didn't workout and then went with another option. My bike is stamped 5-2006 so I'm right in the middle of the trial gear. I've never experienced a gear box issue with any of my bikes in the 35 years I've been riding. I really love this bike but I'm not losing my investment if these things are grenade baskets, and it's gonna be in the back of my head now about the gear. I've got a 94 xr250l that shifts better then this thing. I'll report back when I drain the oil if it's Got metal in it.

[@andrescantor9586]

haspero es man tremendo taller saludos de colombia cucuta

[@jeanvincent7287]

Thanks for the video Rob! What year is the DR and how much mileage was it? I am planning to buy one DR650 used this year and I wonder what year and mileage to look for.

[@robarmstrong930]

+Jean Vincent this is a 2003 with 140 000km on it now which probably isnt much help to you haha. i will say that i had 5th gear explode on this engine at 68000km though so listen carefully for any whine from the transmission if your testing any higher milage bikes

[@jeanvincent7287]

+Rob Armstrong Thanks for the answer, thats way enough mileage for me, my choice will be a DR!!!

[@kentuckyjustice1408]

… near Malaysia... Is that anywhere near the Kentucky/Tennessee state line?

[@domothepilot]

nice video, thanks! your smile when it started =) I have the same problem with the 3rd gear. even worse, one tooth is probably out. It seems there is no quicker way to replace this than taking out the whole engine..right?

[@syafiqani2085]

Very satisfying 😋

[@TonySMotorcyclePassion]

awesome.thankyou

[@walteranthonyocon6768]

Rob, the whining noise for the 5th gear you heard, would that be an indicator for the 3rd gear too? A tell, tell sign, it is about to explode?

[@robarmstrong930]

i wouldnt think so. in 5th gear the load is going through 5th gear so any whine is likely associated with the gear you are in. i do remember a strange whine in 5th gear a few weeks before my 5th gear exploded at 68 000km though so it might be worth a look. its cheaper to split the cases than buy a new engine haha

[@walteranthonyocon6768]

Roger

[@rabbbie99]

I’m hoping the DR600 is very similar as my friend has stripped his down his engine completely to repair a broken kickstart. We will start rebuilding it tomorrow....yikes!

[@neepaninho]

This is such a useful video, nice one Rob. Currently tearing into mine as it's just eaten it's own bottom end bearings. Could anyone think of why this ha happened in the first place? '93 SP43a 40,000 miles, oil delivery seems good, someone's been in there before (split the crankcase).

[@robarmstrong930]

depends on what's wrong with it but could just be that one of the bearings got dropped or knocked hard before installation. you won't feel it at the time but it will shorten the life of the bearings significantly

[@neepaninho]

+Rob Armstrong Got it out and split on the bench. It's only the one bearing (one side), behind the magneto, and hasn't caused too much damage....lucky. Happened on the very last day of a 3 month trip round Europe, on the home stretch. How was/is yours? Oz to Iceland? Oh also, do you know how that bearing is fed oil? Is it through the crank itself from the filter? Cheers

[@robarmstrong930]

+neepaninho sorry for the ridiculous delay in responding. youtube has a terrible way of dealing with notifications or im just doing this wrong. ive never had a bearing issue on my bike, the transmission goes before that haha. i beleive that bearing is fed primarily through the crankshaft along with a lot of splash lubrication from whatever comes off the bottom of the piston after its squirted up there by the little nozzle on the RHS engine casing

[@DRDiaries]

Awesome!!!

[@darrenwilson3732]

Should have de-greased and pressure washed the bike and motor 1st! Great Job overall! Thanks for posting.

[@justgjt]

Amazing..... Had you pulled it down that far before ?

[@TheJagot]

finally thumbs up

[@luissaavedra5948]

Awesome

[@asergeevich]

Bravo! Great job and timelapse ))) Do you use liquid gasket maker instead paper gasket in halfs of engine?

[@robarmstrong930]

yep. used threebond and never need to worry about it again

[@asergeevich]

One more question ))) Need your advice because repair manual don't describe this moment Do you apply engine oil to thread part of cylinder head bolts before tightening?

[@robarmstrong930]

make sure the threads are clean and have a little oil on them. its also a good idea to apply a little oil to the underside of the bolt head and the copper washers. that way your torque reading will be closer to the actual values in the manual. just make sure you only use engine oil. do not use grease or anti seize

[@asergeevich]

Rob Armstrong thanks a lot! Merry Christmas!

[@eliwinter9779]

favuloso

[@badobado9501]

عندي دراجة نارية 650DR احتاج لخدمة منفظلكم

[@rallenrallen]

I would love to see the engine rebuild in real time. Not in 0.25 speed. Too may frames missing ;-) Nice work though 👍🏼

[@sidheart19]

Wow!!

[@ferdinandreinhardfr]

Please Upload this video in Normal speed, it would help me so much! Greetings from germany. :) awesome anyways! :o

[@ronenfe]

It must have been taking days

[@emigrant4life]

I will need 3 days for it minimum))

[@tikoflsilva1115]

Show super pro

[@Finke.]

3rd gear wheelies huh LOL ... good feeling when all fixed ... another happy chappy ...

[@Finke.]

+Claes Månsson Yeah I'm hearing you ... common fault with any type of bike doing a lot of wheelies gear changing while front wheel is in the air not clutching correctly ... resulting in jumping out of gear when backing off the throttle when worn ...