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DR650 Engine Dead, Ideas? DR650 Engine Dead, Ideas?
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Photo by Andy Miller, UK,
Taking a rest,
Jokulsarlon, Iceland



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  #16  
Old 2 Jan 2012
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I am assuming that the engine number is stamped on the main casing? If the casing is OK you could get a replacement engine and have the internals dropped into you old casing and use the replacement barrels and head.

In the UK changing numbers isn't a problem, and bizarrely neither is grinding the numbers off an engine and selling it - or putting said numberless engine into a road registered bike which sounds odd but the DVLA says is fine.
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  #17  
Old 2 Jan 2012
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Cheers and plans
Thanks everyone for your input through the stages! It's been a great learning experience and definitely has an effect on the trip direction one way or another.

I've been weighing up my options and at this stage they look to be...

1. (unlikely) pay $4400 to get the engine fully rebuilt

2. Found a 2008 bike on kijiji with 6200km on the clock and may use that engine as a replacement and pick off the rest of the bike for replacement parts and spares, and possibly part it out. Means I have to pay the $400 engine split and diagnostic fee at the mechanics.

3. Buy the engine from a 2005 bike (from the shop that had a top end rebuild done and the guy didn't pay up) with 7500km on the clock. Will cost $2000 for the engine and they will waive the $400 diagnostics fee. Must ask why it was being rebuilt at 7500km next time I ring.

4. Option 2 or 3 but have the engine put inside the crankcase of my 2010 engine so I can retain the engine number, as Grant pointed out, will be vital to match up later down the track. This can be done without a mechanic I assume.

Any opinions, suggestions and ideas are welcome, no matter how professional or not!
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'10 Suzuki DR650. 2011-12 Sth-Nth Chile-Alaska. Currently in Cairns, Australia. www.followtheakubra.com.au
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  #18  
Old 3 Jan 2012
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I've never worked on a DR engine but I imagine you will need a hydraulic press to get the big end bearings out and in which I'd say is a mechanic job unless you have one at home. Judicious use of a low oven and a freezer might work for getting them back in.

Checking the crank journal clearance would also probably be a good move if swapping internals over as one will have worn with the other so might not fit right when swapped.
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  #19  
Old 4 Jan 2012
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Quote:
Originally Posted by brianrossy View Post
4. Option 2 or 3 but have the engine put inside the crankcase of my 2010 engine so I can retain the engine number, as Grant pointed out, will be vital to match up later down the track. This can be done without a mechanic I assume.
With all the other destruction, are your engine´s crankcases still fully ok to use then?

Then it might be possible, but just beware, that there are several different versions of the DR650, and also spec-codes for different markets (EU, USA, OZ), so I´d advice to first double-check, that all parts are compatible.

And you´re still talking about a major bottom-end operation here. Personally I wouldn´t try it, unless I had pretty solid mechanical knowledge and experience, a garage with proper tools, and the workshop manual to guide me. It´s not rocket-science, but you still can´t afford to make mistakes on that.

Are you at the moment close to making the decision on what will be the best way to go...? It really sucks, what happened, but I guess you were kinda lucky, in the sense, that you were just about to have a break from riding anyway!
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