DR650 Maintenance and problems log

May 15, 2019 — Various

Puncture repair.

Pulse coil replacement.

Maintenance:

0 km (the bike is at 18896 km)

	new bearings front/rear - 5 bearings (Moose Racing)
	new brake pads front/rear (EBC Long Life Sintered)
	new chain (DID 525 ZVMX)
	new sprockets - JT 43T and JT 15T
	new oil and oil filter
	new air filter (Twin Air)
	new spark plugs
	new battery - Yuasa YTX9-BS

+8200 km

pulse coil is dead - used spare part I already had

+10415 km

rookie mistake - when putting back the rear wheel, I forget to put the middle spacer

-	after a few kms, the bearings are destroyed, two spacers are slightly damaged
-	bearings are all changed
-	I changed the two spacers on each end of the axle
-	luckily, damages to other parts are minimal

+23500 km

a bolt on the luggage rack is broken in two - I then notice that that bike rear/left rack bracket is broken

-	new welding of a bracket with reinforcement
-	managed to remove and replace broken bolt easily

+27317 km

changed brake light bulb and headlight bulb

+33607 km
After a 6 months break at home, I have returned to Mexico to retrieve the motorbike and continue my trip. I took the opportunity to bring back some new spare parts. It was not necessary to change them now, the chain could have done a few thousands kilometres more. However, it is easier to buy parts in Quebec, and I installed them when I got back to Mexico. On a motorbike, space is too rare to be able to carry many spare parts.

	new air filter (TwinAir)
	new spark plugs 2x
	new front sprocket - JT 15T
	new rear sprocket - JT 43T
	new chain (DID 525 ZVMX)
	brake light bulb

+43104 km
After a brief three-week round trip home, I bring back a new air filter.

new air filter (TwinAir)

Rear Shinko 705 after ~12000 km (1st set).

Rear brake pad after 23104 km (1st set).

+47482 km
The motorbike was shipped by cargo plane from Panama to Colombia. During my stay in Bogotá, I take the opportunity to go to a mechanic from a complete check-up.

	tuning + new timing chain
	valves tuning
	clutch tuning (wow, a new clutch plate was added)
	new gasket - clutch side
	new gasket - stator side
	carburetor: new float, new slide, new needle, tuning
	oil change of front and rear suspensions
	suspensions tuning
	new engine oil and filter
	air filter cleaning
	chain support
	new spark plugs
	new clutch lever
	misc. screws
	alignment of panniers and racks
	greasing
	alignment of front light! new tires

Maintenance in Colombia (+47482 km).

+52028 km
Most of what was done in Colombia was bad work, thus I had the motorbike checked again in Ecuador. In fact, the mechanic in Colombia was a scam. Some changes he supposedly did were not done, or they were done with used parts somewhat less worn out than the one I already had on the bike.

	valve seals
	carburetor cleaning + new slide + new jet needle
	rear wheel bearings
	new timing chain
	gaskets (clutch, stator, valve...)
	new piston and rings set
	o-ring seal on radiator
	cush drive rubber dampers
	friction clutch plates
	welding and strengthening of the luggage rack and frame
	new rear suspension spring (more rigid)

Sata, mechanic/owner of Moto Hell in Quito.

+57490 km

welding of the luggage rack

+59280 km

fork seals changes

+63590 km
One morning at about 5 Celsius, a screw on the oil filter cover broke after a cold start. I lose all the engine oil. Towing to Iquique.

screw replaced by a custom repair (stud + blue Loctite + 2 bolts)

+70769 km
Panniers repairs at an aluminum workshop.

	flattening
	welding of broken seams
	welding of numerous cracks

Engine oil and filter:

At the beginning of the trip, I was changing oil every 6000 km... After Ecuador, every 4000 km more or less.

0 km	oil change + filter
+5 800 km	oil change
+11304 km	oil change + filter (30200 km)
+17649 km	oil change (36545 km)
+23986 km	oil change + filter (42882 km)
+30234 km	oil change (49130 km)
+33607 km	oil change + filter (52503 km, after 6 months in storage)
+39272 km	oil change (58168 km)
+45418 km	oil change + filter (64314 km)
+47482 km	oil change + filter (64314 km, at the mechanic in Colombia)
+52028 km	oil change + filter (70924 km, at the mechanic in Ecuador)
+56225 km	oil change (75121 km)
+59280 km	oil change + filter (78178 km)
+63590 km	oil change (82486 km, after a screw broke...)
+66717 km	oil change + filter (85613 km)
+70769 km	oil change (89665 km)

Brakes:

0 km	new rear/front
+23104 km	new rear/front (rear 90% gone, front 60% gone)
+39288 km	new rear/front
+52028 km	new rear
+59280 km	new front

Tires:

0 km	Dunlop 606 tires
+1000 km	front tire changed - Trailwing
+5800 km	rear tire changed - TKC 80
+10400 km	tires changed - Shinko 705 (longevity: ~12000 km rear)
+23104 km	tires changed - Shinko 705 (longevity: 16184 km rear, 24 378 km front)
+39288 km	rear tire changed - Dunlop Trailmaster (longevity: 8194 km rear)
+47482 km	tires changed - Michelin Sirac (rear changed at 8743 km, split tire)
+56225 km	rear tire changed - Pirelli Scorpion MT90 AT

Parque Nacional Los Volcanes - El Salvador

New Dunlop Trailmaster.

Dunlop Trailmaster after 8194 km.

Michelin Sirac @ 500 km.

Michelin Sirac at 8743 km, 1 cm slit.

New Pirelli MT90 A/T.

Punctures:

+6700 km	a nail - rear - United States
+10000 km	a nail - rear - United States
+35144 km	a screw - rear (tube replaced) - Guatemala
+37403 km	a piece of metal - rear (tube replaced) - El Salvador
+38501 km	a thorn - rear (tube replaced) - El Salvador
+38973 km	a nail - rear (tube replaced) - El Salvador
+50211 km	a metal pin - rear (tube replaced) - Ecuador
+56124 km	tire has a 1 cm slit - rear (tube replaced, new tire when back in town) - Peru

Road from Cara Sucia to El Imposible Park - El Salvador

First day in El Salvador. A puncture.

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