The DR650 thread

**MarkH** · 12th March 2015, 15:38

This weather is depressing, currently on holiday and my DR is out of commission.
When I turn on the fuel taps I get petrol leaking out from around the fuel bowl, gotta get new o-ring for it.
I would have been having fun riding the gravel roads around Coromandel on Tuesday & Wednesday (camping Tuesday night) if it wasn't for this wee issue.
The weather was looking really good on those days too!

I enquired at the local shop about getting a rebuild kit for my Keihin FCR carb but they haven't got back to me so I've ordered one from Procycle.
I'm currently hoping that it isn't a subtly different model that needs a different o-ring.

My new plan is to fix the carb and mount the side racks (carb parts and side racks are currently on the way) and have the bike good to go for a trip around Coromandel maybe Tuesday & Wednesday, relax and organise stuff at home on Thursday and then head to Taumarunui Friday for the 42nd traverse ride.
On Tuesday 24th I'm back at work and have no more time for riding around apart from weekends.

**Big Dog** · 12th March 2015, 17:11

Originally Posted by MarkH

This weather is depressing, currently on holiday and my DR is out of commission.
When I turn on the fuel taps I get petrol leaking out from around the fuel bowl, gotta get new o-ring for it.
I would have been having fun riding the gravel roads around Coromandel on Tuesday & Wednesday (camping Tuesday night) if it wasn't for this wee issue.
The weather was looking really good on those days too!

I enquired at the local shop about getting a rebuild kit for my Keihin FCR carb but they haven't got back to me so I've ordered one from Procycle.
I'm currently hoping that it isn't a subtly different model that needs a different o-ring.

My new plan is to fix the carb and mount the side racks (carb parts and side racks are currently on the way) and have the bike good to go for a trip around Coromandel maybe Tuesday & Wednesday, relax and organise stuff at home on Thursday and then head to Taumarunui Friday for the 42nd traverse ride.
On Tuesday 24th I'm back at work and have no more time for riding around apart from weekends.

Similar unit on my DR350 does that occasionally. A little deisel stops it, about half a cup in the tank. I am told it is the float not returning fully rather than the O ring.
Apparently has to do with the aromatics combo we use here.
A full clean of the carb a few years ago did stop it for a lot longer but issue returned after about a year. Diesel trick seems to work until the bike is parked up for longer than a week next.

**MarkH** · 12th March 2015, 18:47

Originally Posted by Big Dog

Similar unit on my DR350 does that occasionally. A little deisel stops it, about half a cup in the tank. I am told it is the float not returning fully rather than the O ring.
Apparently has to do with the aromatics combo we use here.
A full clean of the carb a few years ago did stop it for a lot longer but issue returned after about a year. Diesel trick seems to work until the bike is parked up for longer than a week next.

Hmmm, interesting idea and could be worth trying if the rebuild kit doesn't fix it.
The rebuild kit gives me "new O-rings for the Top Cover and Float Bowl, a new float valve with clip and new bowl screws".
The float valve looked OK when I pulled it apart and took a look, but I'll replace it with a new one as well as the O-ring for the float bowl, then I'll see what happens when I turn the fuel taps (1 each side of the tank) back on.

Damn thing was fine on the weekend and then Monday morning I go into the garage to see a puddle forming under the DR.
It definitely looks like the fuel is coming out from around the join between the carb body and the float bowl, I guess that the fuel level could be higher than normal if the float is not returning fully or it could be a problem with the O-ring. Either way a new float valve might fix a higher fuel level and a new O-ring should hold the fuel in so I'll keep my fingers crossed and hope the problem is gone after the rebuild kit is used.

Right cunt of a job getting the carb out and even worse getting it back in, not quite an easy slide in partly because it isn't a DR650 carb.
Bike is really responsive though, gotta love the FCR carb when it isn't leaking fuel all over the back of the engine.

**MarkH** · 13th March 2015, 17:23

Since is still leaks fuel I've pulled the carb from the DR again.
Neither the Honda nor Yamaha shops here can get me the O-ring, NZ suppliers show out of stock and it would take 3 weeks to get it from Japan.
Hopefully Monday or Tuesday the FCR rebuild kit will arrive from Procycle.

I removed the existing O-ring to check it, it is quite flat. I'm guessing that the rubber was once round and has flattened over however many years it has been in the carb, now to the point it doesn't stop fuel from getting passed it.
I'm thinking that if the rebuild kit doesn't match my particular carb I'll try a fuel resistant liquid gasket product.

**speights_bud** · 13th March 2015, 20:34

Before trying a liquid gasket (which I would consider a last resort) it might be worth looking at getting a piece of oring cord a suitable diameter and make your own. But before doing so does anyone know about super glue and petrol? I used to use the loctite equivalent.

**Mo NZ** · 13th March 2015, 20:44

http://www.procycle.us/bikepages/dr650.html#

**MarkH** · 14th March 2015, 01:54

Originally Posted by Mo NZ

http://www.procycle.us/bikepages/dr650.html#

Yep, that's where I've ordered this from:

I'm really hoping it matches my FCR carb otherwise I'm gonna have a lot of fun trying to find the right one.

**Mo NZ** · 14th March 2015, 07:28

I can remember carbs that had a paper/cardboard type gasket.
If you couldn't get the right one you cut one from a sheet.
Maybee you could make one.

**pete376403** · 14th March 2015, 08:00

I have seen O ring kits which have lengths of different diameter material which are cut to size and joined to adhesive . Loctite made such a kit at one time. Might work in this case as the seal is not subject any movement or real pressure.

these guys could help http://www.sealhouse.co.nz/oring-cord-xidc100297.html

**Waipukbiker** · 14th March 2015, 12:36

I don't know about the FCR Carb but I used to remove the throttle and choke cables plus the breather hose from the R/H side, loosen the clamps on the intake and output hoses and rotate the carb around in the hoses so the bowl was facing out the side, the carb could be dismantled with out removing it.

**MarkH** · 14th March 2015, 14:31

Carb is now on garage floor beside bike.
Rebuild kit is now showing as being in Auckland, hopefully delivered here Monday morning.
Side racks also in Auckland and also should be here Monday morning.
I've got my fingers crossed hoping it all works out.

**MarkH** · 16th March 2015, 14:01

Side racks still haven't arrived, but the rebuild kit turned up this morning.
Fitted float valve & fuel bowl O-ring (perfect fit

), put everything back together and turned on fuel taps.
Went for a ride and filled the gas tank (was getting low).
Carb is dry around fuel bowl now, no petrol seeping out.

What has 2 thumbs and is now much happier? This guy! (pointing thumbs to myself)

I might take a ride up to Port Jackson tomorrow, camp overnight and explore the area.
I'll pop down to Taumarunui on Friday for some great riding this weekend.

Once again my experience shopping locally reminds me of why I order so much stuff from overseas.
NZ suppliers have no stock and it will take 3 weeks waiting to get it from Japan, great when I'm part way into a 2 week holiday and will be busy working in 3 weeks.
Procycle beats that shit hands down, put through an order on Tuesday, stuff arrives the following Monday.

**nzexc** · 17th March 2015, 14:05

Who has the B&B rear rack? Would you buy it again and can you still fit the standard grab handles with it?

Has anyone got a rear rack they want to move on maybe.

Many thanks

**R650R** · 19th March 2015, 18:12

Originally Posted by MarkH

Right cunt of a job getting the carb out and even worse getting it back in, not quite an easy slide in partly because it isn't a DR650 carb.
Bike is really responsive though, gotta love the FCR carb when it isn't leaking fuel all over the back of the engine.

The procycle instructions for the Mikuni tm40 mention removing the rear brake reservoir and loosening the airbox mounts (and remove battery hlder I think???). You only end up with an extra half an inch breathing space but makes the difference.

Back to my own man cave, went with the Renthal 983 bars sourced locally for a great price via BikeWorks Onekawa. Slightly less sweep than standard but like the feel, found the Zeta small adaptors to remount the handgaurds so all good.