Suzuki DR650 RSE Restoration Part 5 The Engine installation

[@mandaloreaner]

I´ve done the engine job two times on my DR650 Dakar (38tkm and 72tkm) and I can say: you´re a professional mechanic!!!

[@lunettestp]

I really enjoy your video’s, thank you for this. I hope i can learn how the wiring works in the next episode.

[@ЮрийКурочкин-ъ1л]

Очень полезное видео, впрочем как и остальные. Спасибо!

[@pensativo4788]

I m have Suzuki Dr RS 1995 Nice moto

[@sergiosuarez3170]

Gran trabajo, muy inspirador, yo estoy en el mismo proyecto pero no alcanzo tu nivel, muchas gracias por compartir estos videos

[@seth5369]

bel video. la testata è stata rettificata ?

[@ignaciocanepa6233]

Hi, good work! question: the cilinder comes with separated cilinder sleeve? or the piece is just 1? thanks

[@WolfDog375]

Hi, a very good and informative video. Can you please tell me the reason the valve was broken in the previous engine head? I have heard a few stories of these engines ending in a broken valve, but just couldn't find any info what actually was the cause. Oil starvation to the head making the valve stick and meet the piston? Valve just cracking from temperature? Problems with timing chain and tensioner?

[@restorationvalve]

Hi, As far as I could find when taking apart the engine: The right side engine cover houses oil passages, which feed the top of the engine. Since someone put the cover on with too much silicone or liquid gasket it blocked the oil passages that fed the top of the engine, thus overheating the rockers and valves. After that the valve start to stick and it’s just a matter of time when they hit the piston. I recommend always using a gasket on the right side cover and maintaining regular oil changes. Because the DR650 don’t have any warning systems for overheating, on mine black 1993 I added a electronics thermometer that measures the valve covers temperature.

[@WolfDog375]

@@restorationvalve Thanks for the information. Yeah these old 650's should have a thermometer and an oil pressure light.

[@adventureguy4119]

Mine brand new has had the rocket cover repaired twice for a leak still Leaks some. Is there aera pressurized

[@restorationvalve]

The rocker cover has a oil passage thru one of the dowels that provides the oil for the rocker surfaces. Check the surface of the cover and the head, there might be a chance that there’s a scrape from taking the cover off that doesn’t allow the cover to sit fully down on the head

[@stefanzett9857]

at 10:47 you can see that the rocker arms are worn.

[@emiliendeclercq9987]

How did you get the cil over the piston so easily I ve been struggling with it for over an hour 😂😢

[@restorationvalve]

The cylinder has a taper at the bottom. I’ve just pushed in the rings one by one and the piston usually slides in.🙂

[@collykeogh]

where did you find a good head . hard to find these days

[@restorationvalve]

When searching I found several, for 200-400Euros in Germany, Lithuania and Poland. Found this one in Poland on a page called Allegro.pl for 160Euros with shipping.

[@Cheesem17]

Hi I just replaced my balancing chain without doing the top end, does it matter which stroke the engine has to be? Also when I turned the engine over by hand the alignment marks didn't line up after.

[@restorationvalve]

Hi, it shouldn’t matter on which stroke the cylinder is on, all three shafts rotate the same speed. The marks should align, the chain should have three chromes links that show the placement of the marks, they should alignment after a few turns. Check if the sprocket keys aren’t damaged or missing.

[@Cheesem17]

Thanks for the advice, your videos have been really helpful

[@seth5369]

you have rectified the cylinder head, where are the valves?

[@restorationvalve]

I’ve bought a good used head because repairing the original would have cost more to repair

[@seth5369]

@@restorationvalve only good clean head with oil. not speak English scusa 🙏 🙏

[@nenadpavlovic3266]

at how many nm the clutch cover tightens ??? Thanks !!!

[@restorationvalve]

My service manual doesn’t show the side covers, but I would say that it should be 7-11nm like the rest of the M6 bolts on the case

[@nenadpavlovic3266]

@@restorationvalve thanks !!!👍👍👍

[@arturoterrasi5919]

Where did you find The free whell bearing Min 15.57 ?

[@restorationvalve]

Do you mean the starter clutch? The OEM Suzuki costs 226€, so I got one from Ebay for 37$. www.ebay.com/itm/Starter-Clutch-One-Way-Bearing-for-Suzuki-DR650-S400F-LS400U-LS650-ST400V/264807072471?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

[@mrunivercet1678]

Why not put a brand new piston in?

[@restorationvalve]

The bike came with that piston. I've measured it and it and it was in the service manual specs.

[@Максим-м7п5ч]

the valve cover is placed on the anaerobic sealant. you did it wrong.

[@restorationvalve]

If we look at the Suzuki service manual, it states that the cylinder head cover should be put installed with SUZUKI BOND NO. 1207B, which is an RTV-based silicone sealant. I have used a similar sealant to the Suzuki recommended one and I haven't had any problems with sealing the cover or getting it off when needed.