Cheap or Expensive? Intermittent Failure Repair / DR650 Maintenance

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My DR650 ignition was intermittently failing and the engine would die or not start. I traced it to the terminals at the CDI. Here I show the reason and the parts and procedure to repair. This DR has been a reliable trouble free dual sport carrying me 26,000 miles of trail and road. Over time heavy loads compressed the seat pan which touched the CDI terminals and caused metal fatigue.
See @jrdepew "Gremlin Attack", ORBDR EP3 (RU-vid) where trouble hits. Many more DR650 adventures on my channel.
Electrical parts: www.Cycleterminals.com

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29 сен 2024

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Комментарии : 44

@JagLite 10 месяцев назад

Excellent video! Finding an intermittent electrical problem is usually a long and frustrating search. Thanks for showing us where you found it and how you fixed it.

@jrdepew 10 месяцев назад

Thanks. Stuff like this from others has helped me often. Might be the ticket for somebody.

@johnstahl5699 5 месяцев назад

Thanks JR, excellent video and source information.

@jrdepew 5 месяцев назад

Welcome

@deberryfh 10 месяцев назад

Totally interesting. Keep that puppy running.

@jrdepew 10 месяцев назад

That's the plan!

@DinosTinkerShed 6 месяцев назад

Good morning JR, as I am working through my ignition episode for my channel, I thought how good it would be to link to this video as an example of how to repair the connections on the DR. Would you be ok with a link and shout out to your channel? Thanks Dino

@jrdepew 6 месяцев назад

Absolutely! Thanks for reaching out.

@jasonloke2219 2 месяца назад

*Thanks!* 🙏 a lot. I may have the same problems on my DR650. thanks!

@jrdepew 2 месяца назад

Intermittent electrical is tough to trace. The key in my case was wiggling the connections at the CDI would fix it temporarily.

@glennfryer1539 10 месяцев назад

I had a DR650 out in Sierra Leone just after the Civil War, it was a brilliant bike, reliable and very torquey, never had any issues with it, always started, a good set of tyres and you can go anywhere on it...they are great bikes...

@jrdepew 10 месяцев назад

Agree 100%. This pin fatigue resulted from luggage compressing the seat pan till it touched the terminals. Vibrations did I the rest. Can be prevented.

@mikes4352 10 месяцев назад

Im glad to see you located the problem and that it was a fairly easy repair. Thanks for sharing

@jrdepew 10 месяцев назад

For sure. I was thinking CDI replacement or stator pickup ($$, time).

@tobyhottle9540 6 месяцев назад

I have the Honda xr650l had the same problem. Bad cdi box. Great video!!

@jrdepew 6 месяцев назад

Thanks 👍

@craigcook1571 6 месяцев назад

How much does your bike weigh wet with no luggage😊

@jrdepew 6 месяцев назад

Roughly 380 lbs with 5 gal gas.

@craigcook1571 6 месяцев назад

@@jrdepew👍🏻 have you ever considered getting one of those motorcycle lifts that break down for stowage. That’s what I use to lift my KLR650

@jrdepew 6 месяцев назад

I have. So far, I can lift this DR and plan to ride a lighter bike this season in any knarly stuff. They are fairly heavy themselves but may become an item for me.

@ETA555 7 месяцев назад

What year is your bike?

@jrdepew 7 месяцев назад

2014

@ETA555 7 месяцев назад

@@jrdepew Only 10 years old. Pretty new. What bike did you own before that?

@jrdepew 7 месяцев назад

Bought in 2018. Did the TAT, and many, many trail miles. Mostly rough riding. First bike since a Yamaha 250 in my 20’s.

@PSBEadventures 10 месяцев назад

Great video JR! Nice to know you can source the connector ends!! Thanks for sharing man!!

@jrdepew 10 месяцев назад

Small vendor but has the stuff. Thanks for watching.

@TheInterstellarHobo 5 месяцев назад

Nice find on the problem and sourcing parts. The crimpers are called metri-pak/delphi type and are available on amazon or other places at various pricing. I love my DR as well.

@jrdepew 5 месяцев назад

Thanks for the info!

@ozzielinkin 8 месяцев назад

Thx for posting, I m just starting my search for my problem thsts causing my bike to stall randomly . At first I thought it was a carburetor issue . But teardown of carb showed no problems . So checking the electrical system is next .

@jrdepew 8 месяцев назад

Intermittent issues are hardest to track down.

@elgringoec 9 месяцев назад

Good on you for repairing it. I'll say I've never seen connector pins fail due to fatigue from vibrating. I've seen them broken by people who use the wires to pull the connectors apart instead of the connector bodies. The xr650 has had a known CDI failure mode where internally some solder connections on the PCB get cracked. I cut mine apart, removed the potting compound, resoldered the joints, and buttoned it up with silicone sealant. That was a few years ago and it's been fine ever since. I was going to get a spare but never have.

@jrdepew 9 месяцев назад

That's a creative fix on your part. It appears my plugs were in contact with the seat pan which over time had dished some due to luggage weight and off road riding.

@danielcarroll5667 10 месяцев назад

Great job diagnosing and repairing , I used to work on boats for a living , intermittent electrical problems were my worst nightmare , thanks for the link too , I'm guessing you're back on the East Coast now enjoying the phenomenally beautiful Fall we're having...

@jrdepew 10 месяцев назад

Yep, and planning next year’s adventures!

@RGB872 10 месяцев назад

Excellent info. I’ve had a loose connection in my kill switch that eventually had me replacing the whole switch. Bike has not hesitated since. Thanks for the vid.

@jrdepew 10 месяцев назад

That is another potential spot. I try not to use the kill switch as much as posable.

@seisamigos397 10 месяцев назад

Nice fix JR! Thanks for sharing!!

@jrdepew 10 месяцев назад

Thanks, appreciate you commenting!

@mt1885 10 месяцев назад

Hi JR can you list the tool you use for pushing the pins out and other tools you used?

@jrdepew 10 месяцев назад

The small flat screw driver in the video or similar sized device as shown will release the terminal. The crimping tool is available on cycleterminal.com . It makes a proper crimp.