Hi all. In cusco Peru...it's service time. I have some minor probs that I can fix but would like more info on. Please help!

Horn stopped working. Is this common? Not a switch problem. I checked.

Starter button doesn't work. Seems to be spring inside. Fixed twice now n probs again. Push starting at 4000m blows! killswitch v sticky. Lubes with no improvement. Where can I buy a new assembly? And horn perhaps.

Front end makes clicking sound going over potholes. Bearings?? Or susp? Oberved for loose or leaks. None.

Choking a bit ESP with accel. Mostly at altitude. Read other thread and will try those ptions. How easy is it to clean the jets and how to do it. Should I run some carb cleaner through?

Also how do people keepmya chain cleanmon the road. Carry kero? I've had to use petrol once. How bad is this? What are the other options?

Cheers a mil! Saves me hours sifting through threads while on the road on an iPod.
Rossy.

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'10 Suzuki DR650. 2011-12 Sth-Nth Chile-Alaska. Currently in Cairns, Australia. www.followtheakubra.com.au

Sorted a few things today! Got front and rear bearings replaced easily (10 bucks). A new horn, the old one was shat, 3 bucks. Decided to stick with my current ignition and killswitch setup and botch wire a parallel ignition switch if needed. I´ll play with some springs first as it seems that is the problem. As for the clicking, the head bearings seem fine. Had no problems today after a ride so perhaps was wheel bearings or other. Cheers for your reads and still hoping for a reply or 2!

Cheers,
Rossy.

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'10 Suzuki DR650. 2011-12 Sth-Nth Chile-Alaska. Currently in Cairns, Australia. www.followtheakubra.com.au

Hi Brian,

good to see you sorted out a few things on the cheap!

with the altitude try and remove the side cover of the airbox see if the bike runs better - my 09 DR650 was running rough at elevation in Bolivia/Peru - Id removed snorkel before I left, but it wasnt getting enough air, I ran it without the side cover and it made a big improvement, so I did the 'airbox mod'

Also, make sure the spark plugs are clean, the thin air can make the bike run richer and and blacken the plugs quickly

I see on your blog you are running a stock tank, are you using an in line fuel filter between the tank and carb?

if not then its worth fitting one. I pulled the crappy little plastic filter in the fuel inlet pipe on the carb and tossed it - its way too small and you cant check it visually.

Not sure if the Aussie spec bikes have an EPA blanking plug (like Canadian spec) or the pilot screw on the bottom of the carb is easy to adjust, if you can get to it then you can reduce/increase the fuel flow to the altitude you are riding at. I drilled the blanking plug and have the extended pilot screw I can turn whilst riding.

I found the following settings worked with my bike (clean TwinAir filter, airbox mod done, clean spark plugs)

sea level - 2000m 2.5 turns out
2000m - 3500m 2 turns out
3500m and over 1 to 1.5 turns out.

DR's are not identical - this worked for me, your bike might be a bit different.

if you dont get an improvent after all this, then use a fuel additive/carb cleaner if you can find it - or strip the carb for a clean up.


Id avoid using petrol on the chain, it wont do the 'o' rings any good long term, just get a clean rag and put some oil on it, rub the chain with it until its got a thin coat.

I use whatever oil I have - engine oil is not ideal as its a bit thin, but it will do and its what we all carry. or you can buy something slightly thicker or use some ATF fluid, which works ok too.

chain lube sprays are ok, but they all tend to build up and attract crud, if you have to use them then I have found the 'castrol wax chain spray' works better than most.

if you have to do a big chain clean then id use some kero and a rag - it cuts through grease better and isnt so hard on 'o' rings. then oil chain afterwards.
Dont bother carrying any either, just find where all the bike shops are and get a muchacho to do it for a buck while you slurp on a !!!

Im now using a Scottoiler, which works a treat!

Suerte!

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Cheers
Grif

'11 KTM 450 EXC
'09 Suzuki DR650
'00 Discovery Series 2 V8
'95 Defender 90 300 Tdi Overlander
http://gipperstravels.blogspot.ca

Cheers mate! I'll check these out now. About to service. Great tips. Met some lads yesterday with tips on other for sth America. Peruvians showed me to wrap ya tubes in another tube cut open for more protection. And also to pour used oil on header pipe to stop rust...it goes hard like a blackmpaint!

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'10 Suzuki DR650. 2011-12 Sth-Nth Chile-Alaska. Currently in Cairns, Australia. www.followtheakubra.com.au

Check your carb float level and maybe lower it slightly. While in Yemen my DR didn't want to run at all over 3000m. After having the carb thus checked and adjusted it coped with >5000m passes without probs.

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Cheers,
Peter.

Europe to NZ 2006-10