Suzuki DR650 R Restoration Part 6 Assembling the engine block

We have finally put together the engine block for the 1991 Suzuki DR650 R
Check out the community post to see the parts that are needed to rebuild the engine. It contained OEM and aftermarket alternatives.
Check out the channel updates on:
Instagram: / restorationvalve
Tiktok: / restoration_valve
Check out the eBay store for the spare parts from the projects: www.ebay.com/u...

[@MerBowe]

I didn't have the opportunity yet to disassembly one of these versions with double armonic balancers and the chain inside that operate them, really nice engine, pretty easy to fix and reliable

[@gabrielmoreno1592]

viendo tu video a las 3 am del otro lado del mundo excelente trabajo realizado saludos desde Argentina .

[@TheGamersRace]

I had a 92 dr650 in like 2017 and it on the first day I owned it, the counterbalance chain snapped and it just so happened to stop rotating just out of range of the ceank, so the engine didnt explode. Then after I got it back from the shop (because I wasnt yet mechanically savvy nor did i have the tools to diy) I drove it down the interstate and the old rusted header pipe snapped right off at the flange. Big mad. Luckily the rusted exhaust studs came out clean, and I was able to find one on ebay which I could sand and respray with exhaust paint and primer. Got it back on the interstate, then realized the clutch was slipping. Man what a headache. So I remove the clutch and put all new steels and pads. After all that, I was only like $400 into repairs and I was feeling pretty happy with the bike. Except then the fork seals started leaking onto the front brakes. After all that I was gettin pretty tired of fixing and not riding. 😅. It was a beater and my first road bike, but ngl I still enjoyed it. I plan to get a new dr650 soon.

[@restorationvalve]

Great to hear other owner stories on the DR’s. That’s the main reason why I did a full restoration on this white/red DR, now I can enjoy it as if it was like new from the factory. Great that you can buy a new DR, in my region there are no new DR.

[@TheGamersRace]

@@restorationvalve Yeah the newer motor is more bulletproof imo. The chain driven counterbalancer is a big downside to the old motor. An upside to the old motor is you can modify it with the kick and estart parts. The newer frame is also a plus. It's disappointing you can't get the new ones, they're still for sale at dealers here, but you can buy them used for roughly $3500 USD with relatively low miles. Glad I can watch someone work on these old ones, though. It's sick you could restore one to the degree that you have.

[@gilbartolomeu]

Wow, what an amazing restoration and insightful video. Thank you for filming and sharing the process, it really is helpful for people like me who like to work on their bike and understand how things work and go together. I recently did the balancer chain on my 94 DR650 and this was very interesting seeing how it all works from the "inside". Your bike looks like it just came out of a showroom! Great job, I'm loving this DR650 restoration series.

[@fournierluc7512]

Congratulations! amazing job!

[@user-fq7wp2om5i]

It's too bad that I didn't warm the crankcase before installing the bearings. The second repair will come earlier

[@bogdanstefan6589]

Love you man for your tutorial,very grateful,keep going💪

[@user-pp5ss5du6p]

Привет

[@user-pp5ss5du6p]

❤

[@jeangaelcognat4988]

Merci pour le partage et le montage

[@mairisja]

Thanks for another angle for assembling the engine. Any idea if SP43B engine gearbox can be replaced with a gearbox from SP41B?

[@restorationvalve]

The gears should be the same. To verify that you can check the part numbers between the engines from part diagrams. I usually use this page: suzuki-motorrad-ersatzteile.de

[@mbw201d8]

Great video, mate! I have one question for you about the DR. My crank spring is broken. Is it possible to change it without disassembling the entire engine?

[@restorationvalve]

Thanks, If you mean the kick starter spring, then the only way to replace it is by splitting the case. You can see in the video that the spring has to be installed before bolting the case together, and it’s not accessible from the side covers.

[@mbw201d8]

@@restorationvalve Yes, I mean kick starter spring. I will try to pull out engine, first. Thanks!

[@iDrxn]

Are you using JIS screwdrivers? Or do you replace the screws?

[@restorationvalve]

Yes, the impact drive screwdriver has JIS bits. I kept most of them, replaced the ones that were damaged already.

[@laukinisB]

Hey, nice built. These bearings are not OEM?

[@restorationvalve]

I didn’t order OEM bearing because of the price difference. The ones I used are made in Japan from well know manufacturers. Some of them might be supplying Suzuki with the bearings.

[@laukinisB]

@@restorationvalve last winter i rebuilt my dr 650 r. I used OEM bearings and they cost a lot! could you make a list with bearing numbers? I think this would be useful for those who are going to rebuild their engines.

[@restorationvalve]

@@laukinisB yeah, that’s a good idea. I will include a parts list that’s needed to refresh the engine in these engine video descriptions.