$500 Marketplace Suzuki DR650 Repair Did Not Go As Planned!

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In this video I start to repair a leaking base gasket. While attempting the repair I broke off a Head bolt and had to completely disassemble the motor so that it could be sent off to the machine shop.
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MarleyJaxGarage@gmail.com

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28 апр 2022

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Комментарии : 48

@BillySBC 2 года назад

Looks like you got a really good buy on this bike, and the video is very clear and the camera angles are really nice. Nice editing too. Thanks for posting this!

@MarleyJaxGarage 2 года назад

Yes I am really happy with it so far. Comments like these are awesome to read and keep me motivated.

@douwe4549 7 месяцев назад

I know a mechanic or two, you sir are the real deal! And as somebody else stated here, you will never be out of a job. And also compliments about the filming angles, light and explanations. I could almost do it myself now, almost, sadly i miss your talent!

@neiljarvis8911 Год назад

Great video! You were really unlucky with that head bolt, but not as unlucky as the previous owner - it cost him far more once he'd realised it was beyond his skills. In the future, the world will be full of broken machines, going for scrap weight as there are fewer and fewer people capable of fixing them. Nice to see someone so young getting into it and wining big!😀

@MarleyJaxGarage Год назад

Thanks for watching and I appreciate the comment. There is not much that is more satisfying than starting and riding something that was broken and put to the side.

@igotakai5644 Год назад

10:39 So I rebuilt another DR650 motor and thought I was going to have the same issue but what saved me was actually tightening the other bolts back up a bit then removing the stubborn one. My thinking was if one is still totally torqued down and the others are not, the added tension on the one bolt (instead of being spread equally between the 4) would make it even harder to remove. Maybe yours what stuck no matter what, but it's something I will definitely keep in mind from now on just in case that's what happened. Hope all is well

@trevorjameson3213 2 года назад

I remember taking down my '16 DR650 to install a high-comp piston, a Web223 cam, and a TM40 carb. Pretty easy project overall, but it really wasn't worth the money and effort to get just a little more mid-range and top end power. It was good experience though and a fun project. I should have left it alone though, that big 650 single already has massive torque down low and a nice fat mid-range. I ended up selling that bike and buying a new '21 model because I liked the white color scheme. This time I'm left it stock except for the fuel/air screw adjustment.

@MarleyJaxGarage 2 года назад

Yea it wasn’t too bad of a project. I don’t plan on doing too much more to it except maybe re-jetting the carb.

@notsure9033 Год назад

Hah, I too have a '16 DR650. I was all set to go with an FCR39 Carb and new exhaust, but the BST40 runs just fine with a shim and snorkel removed. Had a bunch of people telling me to drill holes into the air box, but the bike runs just fine. I think I'll leave it.

@elobiretv 2 года назад

Wow thanks for posting this at the perfect time. I'm taking apart one of these engines and the manual says to remove the castle nut holding the crank bearing on behind the flywheel but I don't want to pay £100 for a tool I would use once so I've been trying to find someone who's done it this way.

@MarleyJaxGarage 2 года назад

Yea my bearings were fine so I didn’t want to buy that tool. I had read about doing it that way and glad it worked out. I am putting it back together now so hopefully that video will be up in a week or two.

@igotakai5644 2 года назад

Just tore mine apart last week, waiting for some parts still. Looking forward to the next video. 👍🏽

@SMHman666 2 года назад

Thanks for uploading this. Not planning on doing this but it's good to see the internals and the processes involved in dismantling. Shows the importance of good, clean oil for all those bearings and surfaces too. Bugger about that head bolt but there is always one, lol. You must have been thinking, "This is going smoothly....", Lol.

@MarleyJaxGarage 2 года назад

Yea I was surprised that no one had a good video rebuilding one of these. They are probably on of the most simple motorcycles ever made. Rebuilding it now and hoping there aren’t any more accidents lol.

@johnl9977 10 месяцев назад

Bet you put some never-seize on the new cylinder bolts.@@MarleyJaxGarage

@mikes4352 2 года назад

Fantastic walk through. Ive never had mine apart, it was great to see the procedure. Thank you much for sharing

@SmalltimR 2 года назад

Awesome video - very informative and a pleasure to watch!

@johnwhittington1079 Год назад

You are quite talented. Awesome work!! I’ll be referencing this whenever I’ve got my DR in a million pieces.

@brucehelppie6119 2 года назад

did a previous owner overtighten those headbolts? snapping off that bolt would be my luck, too. great video and explanations of the procedure.

@MarleyJaxGarage Год назад

I’m not sure. I didn’t really get much history on the bike. It seems like I was the first one in the engine. I think it was just seized from all the heat cycles. Whenever I see a head bolt that is long and goes through the cylinder I get a little nervous.

@coryjs9646 Год назад

Damn that was a good video. At 40k I'm looking at 67psi of compression on my DR even at WOT so I'm looking to do some of this work. I hope I don't have the same trouble! Showing step by step is great for someone like me. Thank you.

@MarleyJaxGarage Год назад

Make sure to check your valve clearances. The valve and seat wear over time and can cause clearance to be too tight holding the valve open a little. It will cause a loss of compression. I would definitely do a leak down test before taking it apart. These bikes last a long time when taken care of. Hope you get it fixed up and let me know if you have any questions.

@TepcoCycleRepair Год назад

Do a leakdown test, it has an auto decompression so that amount of compression with auto decompression isn't bad. A leak down will answer any questions and tell you if/where you need to target your repair.

@user-gr6qn1hz6h Месяц назад

awsome video mate, very helpful so far

@jasonloke2219 7 месяцев назад

Thanks a lot for sharing!!!

@kpex7509 2 года назад

Excellent detailed video sorry had to go to all that trouble you make an excellent mechanic🖖🏻🧔🏻‍♀️🇺🇸

@MarleyJaxGarage 2 года назад

Thanks man I actually enjoy doing full rebuilds and this bike was super simple. Now I know exactly what it looks like in there.

@Ian-bq7gp 2 месяца назад

Spark eroder will get seized broken bolt out or centre punch and drill it.

@bigjay6743 2 года назад

When I get a bolt like that sometimes I'll Weld the top of it just to get the heat to go right through it It gives you way better odds of getting it out.

@MarleyJaxGarage 2 года назад

Before I broke it off? I thought about it but the bolt was so long and I still had hope. I did try once it broke off a bunch more times than shown but it just wouldn’t come free. The machine shop couldn’t get it with a reverse drill bit either.

@Ian-bq7gp 2 месяца назад

Sometimes you can unsize it with heat, penetrating oil and hitting the top of the bolt. Steel in aluminium doesnt go well together and vcan seize but copperslip grease between threads in assembly helps it not to seize.

@Ian-bq7gp 2 месяца назад

A new improved aftermarket 3rd gear pinion and cam chain tensioner and neutral sending switch problem sorting out is well worth it.

@cornholius 2 года назад

Damn $500 is a steal!

@MarleyJaxGarage 2 года назад

Yea every now and then I get lucky on fb marketplace. I am also on it way too much so that might be another reason.

@brymanable 3 месяца назад

I really like ❤ this bike how do you guys get these deals 🙏

@johnwhittington1079 Год назад

I have a question. The head looked like maybe it had a paper gasket on at one time? I have pulled my head off and put hondabond on and it’s still leaking. Is it possible to use a paper gasket for the head?

@MarleyJaxGarage Год назад

I am guessing you are talking about the valve/rocker cover? I don’t think they ever made a gasket for that. I would make sure it’s flat with a straight edge and clean of all old gasket maker. I use a thin layer of yamabond just make sure you let it sit and dry for 24 hours.

@ronenfe 2 года назад

32:00 you lost a screw. Also there is an oil jet which it's written that it should be replaced.

@MarleyJaxGarage 2 года назад

The screw just fell through the case onto the table, just didn’t show me grabbing it. I checked/cleaned the oil jet and everything seems fine. I didn’t really do a complete rebuild, more of a clean and inspection of all components. Thanks for watching.