Today I install a ProCycle jet kit on a Suzuki DR650. 

Thanks for the catch, I reviewed the footage and I thought I had that covered but I realize I only showed the spacer in the schematic from procycle. thank you for making note of it. Dino

@@DinosTinkerShed I only mentioned it because everything else was super detailed. I thought you had a fubar moment there and wanted it erased from memory :)

@@calmistheway I just took apart my carb. Guy before me did the procycle needle, but there's no D shaped spacer...? the absence of which would shave make 4mm off the distance the spring compresses. I dunno what this would change...

@@bjeff1981 I really can't comment on your set up without more info? How was the bike when you got it from the guy who did the needle? I have no idea if he is a mechanical wizard or just forgot to put the D spacer :0 . My "complaint" here was that the Procycle kit has specific instructions and the D spacer and it's placement below the "shelf" is critical. Dino skipped over it so I whined :)

Wow, thanks! glad you enjoy them. Dino

so glad you enjoyed it Dino

Thank you so much, I really appreciate your comments Dino

I am glad you enjoy the content. Dino

I do like my morning coffee. Thank you for the comment. Dino

My pleasure, glad you found it useful Dino

I am so happy my video was able to help you out and that your bike is running better. The k you for commenting and letting me know. Have fun riding. Dino

Thank you Jason, I am glad you find the video useful, have fun with your new bike. Dino

Hey, thank you for the advice, I think I have some aluminum angle laying around, Ill try that thank you. Good advise on the cable lubing as well. I have a lot of good friends who are mechanics and have helped me out over the years with questions and explanations on how to to do things better, like your comments. A good friend once told me "you don't know what you don't know" so I try to keep learning and asking questions. Thank you again for taking the time to comment. Dino

Glad it was helpful! Dino

LOL, you can watch them in any order you like, I just hope you like them 😬. Thank you for the comment and the greetings. Dino

Thank you RJ, I am flattered, I am really glad you find the content useful, you made my day! I was hoping to produce videos to walk people through the steps and give them a look at what they were in for even before they tackled a project like this, I am so happy to have spent some time in your shop with you 😉. As for the front suspension, I do have a fork seal replacement video that outlines the internals, but I have not yet determined what I want to do if anything to upgrade the front end. I am currently working on a rear end service video series that should be out in a few weeks or so, and that may help me to figure out the front end as well. Thank you again, I think I read your comment half a dozen times, it is a very nice comment to send. Dino

You are very welcome, I'm glad the content is usefully. Thank you for the feedback. Dino

I am so glad my video was helpfully and it sounds like you are well on your way to a nicely set up carb. Once I get my carb set up and I ride it for a while I may go the additional steps you have done in another video. Thank you again for taking the time to pass on your experience it is appreciated Dino

I'm glad the video was helpful, enjoy the DR Dino

I am glad your project went well, let me know how the tuning goes Dino

Ps, we did a camping travel vacation and pulled the toyhauler from MN to Louisiana to New York and then home. Letchworth State park is quite a sight and a great place to motorcycle and see the history. Thank you again for the help

Thank you Mal, very wise words for sure. As always I love to see your comments. Thanks again Dino

Glad you liked it Dino

glad you are enjoying the content. thank you for the feed back. Dino

Glad you enjoyed it, thank you for the comment Dino

So glad you find the channel helpful and hope you find your DR soon! There a fun bike for sure. Dino

Glad it was helpful! thank you Dino

Glad you enjoyed it

Glad you are enjoying the channel and congratulations on your new to you DR. Dino

Great tips! Thank you for the input and I'm glad you enjoyed the episode. Thank you for the comment. Dino

Thank you for the comment Dino

Good information, thank you, I am hoping that using the smallest of the main jets provided and teh fuel screw I will get better cold starts, and no decrease in mileage, we will see of course but I am hoping. I think you are right about the trails, My daughter and son in law live in Erin so I'm hoping for some day rides in the next week. thanks for the comments Dino

Thanks for the tips! Dino

You’re welcome 😊 Dino

Glad you enjoyed the content. I'll defiantly be doing a tuning video once I can get out. I will be doing some susspention work this winter but I'm just not sure how far I'll go this time or what direction to go in. Susspention upgrades can be a bit pricey lol. Thanks again for the feedback. Dino

Wow, sometimes those screws can be brutal for sure but it sound like you won in the end. Please keep me posted on how it runs. Dino

It started and ran much better, a bit of popping on decel but throttle off in 4th gear it just slowed down like normal. When I played with the fuel/air mixture screw it did not bog down when I turned it in, kind of surprised with that, not sure what it means. Pretty much done now for the year and will do more research and start more tuning in March. I put in the 155 main jet just before I put the carb back in the bike after getting a msg from JD Jetting. Thanks for your help Dino@@DinosTinkerShed

Thank you for the comment and great video idea. I have not done a video on winterizing, however you are correct that is a very good topic, and I will add this to the list. I am a few weeks away from putting her away yet though LOL. Thank you again. Dino

Lol, I would think someone who operates cranes should know a thing to two about cable maintenance. Thank you for the feedback. Dino

Good question about float height, Float height, controls how much or how little fuel is allowed to fill the float bowl. The factory tells you what the height range should be and as long as the float is within that range the carburetor should operate correctly. Too high or too low can lead to flooding or fuel starvation issues. Since the float adjustment is sensitive it can get knocked out of range when rebuilding or cleaning your carburetor, so checking the height and adjusting when required is good practice. I hope this is helpful. Dino

Good product for sure. Thanks for the tip. Dino

Thank you for your feedback and I believe you are right about the EPA regs forcing manufactures to lean out the bike as much as they can and make it tamper proof as well. I am not a mechanic, but I believe backing out the screw helps with the miss firing especially when decelerating with a closed throttle. You do not need the aftermarket to do this adjustment, but it makes it easier as there is not a lot of room to get a screwdriver in there. All you need to do is remove the blanking cap and you can adjust it. Dino

LOL thank you for the kind words, I am flattered, but I have lots to learn and there are many others out there than know way more than I do about the DR and motorcycles in general. My goal for this channel it to bring everyone along as I learn about the DR and other things and we learn together. Thank you again, I do appreciate the complement. Dino

Thank you for the comment and question. I really only upgraded this to help with cold weather starts. When I bought the bike it was very difficult to start on colder days while my fiends was easy as pie. His had the adjustable pitot screw and when we talked to the previous owner he indicated he was also having cold start issues which the screw solved by allowing him to add fuel to the pilot circuit. I decided to install the entire kit just to allow both the low speed enrichment and allow some gentile tuning for the main jet. Performance was never really a goal of mine, just better overall carburation. I have not seen any drawbacks to installing the kit and my DR now starts and runs great on colder days. I don't really track my milage super close but I have not really seen a great increase in fuel usage and still seem to be around 5l per 100km. Hope this helps. Dino

Glad you enjoyed the episode. my understanding is that if you are not going to mod the air box and have not replaced the stock exhaust that the stock jetting is the way to go. Thanks again. Dino

@@DinosTinkerShed p.s. loved the Karl surprise drop in :)

@@DinosTinkerShed also - I've been up to Niagara Falls (US side) twice - one of the coldest places I've ever been. The falls were frozen, and amazing looking. Somehow (low humidity?) I wasn't the most miserable cold though. The wind in Buffalo however, was harsh.

I think Buffalo is on a whole other level. Being on the west side of lake Erie they get cold wind and some of the most snow in the area, Hard to believe the difference 20 miles can make in weather. Thank you for the comment! Dino

I have looked at the smart carb and they look very tempting. The cost is a bit prohibitive for me though. If they sent me one O would definitely do an install video. Dino

Great tip, thanks for sharing. Dino

The mod you are talking about is outside the scope of the ProCycle kit but could be done along side this installation. I believe the idea is to quicken the lifting and dropping of the slide making throttle response faster. I may do this in the future but my main interest with this installation was to get the adjustable fuel screw in place and to richen up the over all mixture. after I see how this works I may elect to also mod the slide and spring as you described. Thank you for the question. Dino

I am no mechanic and I am not sure if the factory settings for the Dr650's carb would be the same, however the fuel mixture screw is factory set between 1 and 1.5 turns out normally. ProCycle says to set their fuel screw 2 full turns out initially, I did this with mine and it ran good even before I tuned it. I would suggest setting the screw at 1.5 turns and see how this works. As for the overflow of gas, have you had the carb apart? did you clean it? If so I would check a few things 1- Is the float height correct? I do not know what the height should be for this carb but a little online research should provide you the answer. Make sure you set this correctly or the bowl will either overflow or you can starve the bike for fuel. 2- If you had the float and the float needle out did you blow the passageway out? I have had the needle seat fall out doing this once and the float needle will not seat allowing fuel to continue to flow even if the float height is set correctly. I normally test this with the float bowl off and the float hanging free. I gently blow air into the carb fill tube with my mouth and then raise the float with my finger. when the float reached its correct height you will no longer be able to puff air past the float needle. Is this information helpful? again I am not a mechanic, just a guy who likes to tinker. Dino

I actually made the mod in my head but testing it proved to run to lean. Here is the link if you want to see ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-svSKv8XqoRY.html but again I ended up not using it. Although I have not yet given up on the idea yet. Thank you for the comment. Dino

Hi Marco, I could head over to the Roman Cheese shop here in Niagara, they are a local Italian store that has all the imported beans 😊, as for the procycle kit, I really don't have an opinion as I have only used theirs. It had the fuel screw I was looking for and a good assortment of jets. I am sure others would be equally as good. Dino

I did not really notice any change, its not a huge set up in jetting and I rarely ride WOT. I think riding style would have more of an impact than the kit itself. Dino

It is a really inexpensive storage box that I purchased at Princess Auto. I have it mounted to the rear rack with threaded nutserts so it can be removed quickly. It is not all that robust but I use it for daily storage of items. Dino

I think there is some improvement but I think it's more in the throttle response and low end drive ability. I would not expect great improvement with the kit on its own Dino

@@DinosTinkerShed I had purchased a ProCycle jet kit a couple years ago, but I have not gotten around to installing it. I think my DR650 runs pretty good now. I would hope that all the work involved installing the kit is worth it.

@@DaveCarlson01 for me it was as it really improved the cold weather starting and idle. However I was never looking for power gains.

I live in California, so cold weather is not a problem. 😁

Hi Blair, thanks for the question. I ordered mine strait from procycle in the states and they shipped it straight to me. I am not aware that there are any Canadian distributors. I will admitt that shipping and exchange is a bit of a deterrent right now. You could email procycle and see if they have a Canadian distributor. Thanks again for the question, and you must have lots of great roads to ride around London, I'm from Woodstock originally and I know there are some great roads there. Dino

New ones came with the kit, you do not have to do this but the bike is almost 15 years old so it is not a bad idea to do so as they do dry out over time. If these leak they can cause the float bowl to overfill

@@DinosTinkerShed Makes sense! Thanks

Here you go, procycle.us/product/85-jet-kit-procycle-stock-bst-carburetor

@@DinosTinkerShed Thank you!

@@DinosTinkerShed Unfortunately, the new DR650 cannot be sold in Europe since 2002 due to EU restrictions. Therefore, aftermarket parts are difficult to obtain here, but I will try to ask an American uncle to bring them home to Hungary.

Thanks for the question. I chose the PC kit because the FM screw came with the kit. It was about the same cost

@@DinosTinkerShed interesting. Can you send me the link to the one you got with the longer screw included because i can't find it

@@TheKingOfKings818 procycle.us/product/85 Try this link. Dino

Not really, to me it seems about the same, but I did spend a lot more time on faster highways last ridi g season so it's hard to really compare with when the bike had the stock jetting. Thanks for the question. Dino

Hi and sorry for the late reply on this. just for clarity it only does this in 4th gear? no other? Dino

@@DinosTinkerShed im still trying to fix this blip but no, it does it in 5th gear too. BUT it ONLY does it from wide open throttle and letting off throttle ever so slightly it does it for a split second then goes away. But if I completely chop throttle, not just slightly from WOT it wont do it.

@@DinosTinkerShed you think I should go to smaller main jet or larger? Other than that bike runs great. Like I say stock airbox with aftermarket slip on. Needle on 3rd knotch. I tried 2nd knotch but seemed to perform better at low and mid range on 3rd knotch. I just get this stupid hesitation for a split second in 4th and 5th gear from WOT and just barely letting off throttle it does it. Im at 1,300 elevation. From Upper Michigan

OK, I am just heading into work and want to think about this, please remember, I'm not a mechanic but just a guy who tinkers. I want to share this with a buddy of mine as I want to give you the best answer I can. Carbs can be a bit frustrating and sometimes require a lot of trial and error. Dino

@@DinosTinkerShed thanks Dino! Appreciate it! Was reading a thread that said if you slightly roll off throttle from wide open throttle if it hesitates that half second or so its to rich. I kno in your video when you initially tuned the procycle jet kit you said the 145 was to lean and actually sped up when rolling off. Cuz I was gonna try to go down to the 145 from the 150

Hi Chaise not Chase, thank you for the comment. As I have said in the past I am not a mechanic but I am willing to offer what knowledge I have to try to solve the issue and you can always call ProCycle as well, I am sure they have had more experience with their product than I have as this was the first time I had used the Jet Kit but here goes my thoughts. 1- If it started without the air filter than died out I think you are right, and it is running rich. Before I tore into the carb again I would try a few things a- Remove one of the spark plugs and see if it is wet or dry, this will help to confirm if it is running really rich b- I would try turning in the fuel screw one turn to see if this helps with the starting or not. c- I would also make sure the choke plunger is seated correctly and not stuck partially open. d- Check to make sure all the vacuum line are still in place and did not get bumped during final install of the carb. e- I would turn off the fuel, let the bike sit for a while and then try to start and run it without turning the fuel on, this will stop any new fuel from entering the bowl if the needle and seat are not sealing f- Did you remember to cap off the vacuum port for the stock petcock? with the new achebis this is critical for the bike to run right. 2- If these do not help, I think you will need to check your work internally. a- make sure the fuel screw O-rings and seat are all in place, this will require you to remove the screw, also double check you removed the original O-ring in the bottom of the whole or you will end up with two o rings stacked on the bottom of the fuel screw. b- Make sure you did not loose the small O-ring under the vacuum cap and that the slide bellows did not get put in incorrectly. c- Check to make sure you installed the correct main jet for your application, the numbers are very small and can be mixed up if you are not careful. d-The last thing I would check is the float assembly while the carb is off the bike, recheck the float height and also I would gently blow in the fuel pipe (very gently not with compresses air) with the bowl off the carb and while gently pushing up on the floats to seal the circuit. If the float needle does not stop the air the needle seat itself may be damaged, Most likely this is not the issue but it is good to check. Again, I am not an expert but this is where I would start. and I would contact ProCycle as well, and they may have seen this before and have more information for you than I can provide. Please let me knw how thigs go. Dino

@@DinosTinkerShed Thanks Dino! I've started running through some of your troubleshooting steps and right now I'm at the point where the carb has just come off the bike. Interestingly, the intake on the cylinder head is quite saturated with fuel. When I pulled the plug, it appeared damp, but I am not an expert. From here I'm going to move the clip on the needle up one from the 4th notch as recommended by ProCycle to the 3rd notch which I understand would lean out the mixture.

Yes that should lean it out. Please keep me updated

@@DinosTinkerShed Great news! I have the bike running (reliably) and driving. I ended up noticing something with the needle that may have been the knife in my back. You know the D-ring that sits on top of the needle and sits level with the little shelf? I noticed on this reassemble that when I was reinserting the plastic assembly, the needle was getting caught on the intake area before fully going into the hole, and when it did that, it moved the D-ring so that it sits on top of the shelf. I have no idea if that was occurring before, but I reassembled it all once more, put more gas in the tank, and now it runs! Only issue I'm having now is it is real hesitant when I lay on the throttle. If I lightly "gun it" it will rev, but much slower than it should be, and if I heavily "gun it" it will start back firing. Went both ways on the fuel screw and the results were the same. I think tomorrow I will check the vac hose and make sure it is 100% closed off.

Sounds like you are making headway for sure. When you put it back together after you figured out the issue did you place the needle back at the 4th position or did you keep it in the third grove? Dino

I did the jet kit on my DRZ and it was really easy. I have no experience working with carbs but the instructions are clear and easy to follow. I just ordered this procycle kit for my DR and i am looking forward to installing it.

It's not too hard to do, as pointed out the instructions are clear and straight forward

@@DinosTinkerShed Thanks , Im just leery of removing the carb, hope I won’t have to

@@bobclapper2672 I took mine out, but I have seen others perform the process by just rotating it. If your uncomfortable just continue to research the process until your confidence is where it needs to be. If you don't feel you want to tackle it that's ok too, no right or wrong way, just have fun. Dino