Suzuki DR 650 Blown Main Bearing

[ironmonkey007 1]

Hi All,

I have a 2018 Suzuki DR 650 with 50K and a blown crankshaft bearing.  A mechanic advised this will require a full top/bottom rebuild and that I may be better off trying to find a replacement engine.  The bike has personal value to me, so I'm looking to keep it running.  Outside of standard maintenance (oil, chain, valves, carb clean) I've never gotten into an engine before, nor do I have a garage to do so.  At this point I am trying to consider my options to fix or replace the engine locally.

Can anyone recommend a reputable thumper mechanic up for a rebuild? Or willing to work with me on a rebuild project?

Any advice on how/where to find a reliable replacement engine in the area?  

FYI, here was my original post with some pics and a description of the issue.  As well as a vid of it running with the blown bearing.

https://drriders.com/blown-main-bearing-t30050.html

Thanks!

[Mr.JAJA 418]

3 minutes ago, ironmonkey007 said:

Hi All,

I have a 2018 Suzuki DR 650 with 50K and a blown crankshaft bearing.  A mechanic advised this will require a full top/bottom rebuild and that I may be better off trying to find a replacement engine.  The bike has personal value to me, so I'm looking to keep it running.  Outside of standard maintenance (oil, chain, valves, carb clean) I've never gotten into an engine before, nor do I have a garage to do so.  At this point I am trying to consider my options to fix or replace the engine locally.

Can anyone recommend a reputable thumper mechanic up for a rebuild? Or willing to work with me on a rebuild project?

Any advice on how/where to find a reliable replacement engine in the area?  

FYI, here was my original post with some pics and a description of the issue.  As well as a vid of it running with the blown bearing.

https://drriders.com/blown-main-bearing-t30050.html

Thanks!

That can be a loose flywheel nut. Have someone open the flywheel and clutch side before making any big decisions.  

[Mr.JAJA 418]

Bring it to the techday on a trailer if possible. And we will have a good look.

[tntmo 963]

Some motorcycle engines have a "rebuild kit" available that comes with a new crank, bearings, seals, gaskets, etc so it's simple to figure out parts costs but a quick search online didn't show anything like that for the DR650.

Without digging through the entire Suzuki parts file, I'd guess it would be around $300 for gaskets, seals, bearings, etc.  Probably about the same for a crank, maybe more.  If you are looking to replace the piston and cylinder as well, looks like ProCycle has the piston kit for $270, getting the cylinder re-Nikasil'ed is only available at a few places (Millineum Tech is the place I've used in the past) and I can't recall how much but probably over $200?  

Then if you need machine work, like getting valve seats cut or the cylinder head surfaced that all adds up.  Replace the clutch?  Cam/rockers all in spec?  Transmission gears?   You might be looking at upwards of $1500 just in parts and machine work.

I've gone through engines like this before, it doesn't take long for it to add up.  If you're doing it yourself, then the labor isn't a big deal but if you're paying someone it's a lot of man hours. It's  2-3 hours just to remove/replace the engine, the last time I had someone with a blown up DR650 that's what we did.  Found a reasonably priced used engine and swapped them out.  

My son had a Yamaha R6 sport bike with a bad engine, the main and rod bearings were going out.  We found a used engine and swapped it out, then I took apart the old engine and sold individual parts on Ebay for twice what we paid for the used engine.  That's an option, although it does take time and some work.  

If you're free next weekend, try to bring it to the tech day like Udo said. 

 I will take a look at it and we can have a cool drink and discuss options. 

 

Edited February 14 by tntmo

[tntmo 963]

Here’s a pretty cheap bike not too far away.  Could pull the engine and part it out?

https://www.facebook.com/marketplace/item/1073297961154211/?mibextid=wwXIfr

Edited February 14 by tntmo

[DSM8 407]

just currious if you drained to oil and checked filter it would be sparkly if a main bearing went out on you, like others said bring to tech day if you can we can get a good look at it and you will be better informed on whats going on, might not be that bad....like Udo said.
Loos nut behind the wheel (or bars your choice)

 

 

Edited February 14 by DSM8

[bajadog 25]

I recommend Mark at DMC performance in El Cajon. He rebuilt my 660 Rhino that sucked in an exhaust valve. Did a great job and wasn't crazy expensive.

Address: 1948 N Marshall Ave suite 105, El Cajon, CA 92020

 

Phone: (619) 929-6339

 

Just my 2 cents.

[Zubb 1154]

Wish I could be there. These small engine bikes are a great mystery to me. Would love to look over Tom/Udos shoulder while they dissect the cadaver. 

[DSM8 407]

2 hours ago, Zubb said:

Wish I could be there. These small engine bikes are a great mystery to me. Would love to look over Tom/Udos shoulder while they dissect the cadaver. 

We will be happy to take your apart any time bring it over (no guarantee on reassembly)

[DSM8 407]

I read his thread in the DR forum. This was in his oil.
As Udo would say (German accent on) Diz not Goot

[tntmo 963]

I looked on the Suzuki parts diagram and didn’t see those parts.  

[DSM8 407]

4 minutes ago, tntmo said:

I looked on the Suzuki parts diagram and didn’t see those parts.  

round thing is the magnet from his drain plug, metal strap looks to have come from the main bearing cage which is a exposed ball bearing type of main.
That is my guess

 

[tntmo 963]

Yeah, I was being sarcastic which doesn't come off too well in a forum. 

With a bearing cage busted off like that you have possibly wiped out your top end as well.  The cam rides directly on machined surfaces of the cylinder head, having debris running through the engine could destroy those surfaces along with the cam and the rockers.  Every bearing in the engine should be replaced to prevent further damage.  The parts bill is going up. 

Sad to see an engine get destroyed like that, no way to tell without complete disassmebly.  I didn't read all the pages of the DR Rider link until now, I hope you didn't try to ride it the 20 miles you were discussing?  Have you removed the oil filter and looked at that?  If it's full of glitter that's no bueno, and I imagine it will be.  

[ironmonkey007 1]

Hi All,

Thanks for the responses.  To answer some of the questions...

Yeah I dumped the oil and saw part of the bearing cage attached to my magnetic drain plug.  I can't recall if I saw anything in the filter but I don't think so. It was the bearing casing that stood out. 

When the issue originally happened I was riding up in Idyllwild and noticed a loud knocking sound.  When I dismounted I saw oil leaking near the base of the engine, near the starter motor.  I threw it in a U-Haul and drove back to SD, then had a mechanic take a look at it. He said it was shot and needed a full top/bottom rebuild. Afterwards I did end up riding it about 10 miles to storage.

The original issue actually happened July 2023, but I was heading out of the country so I ended up storing the bike until I got back.  The video is from last week when I got it running again (new battery, plugs, carb clean). 

The mechanic who originally took a look at it gave me a parts list.  All the parts, bearings, gaskets, etc. (cost ~2100, not including labor)...I believe it was the crankshaft replacement that was the most expensive part. I did check with ProCycle and they do not have a DR 650 kit but told me I could send them the parts list for a quote.

It does sound like finding a replacement engine is the most cost effective option.  I was a little concerned about how that might work with updating the Title? I sometimes ride outside of the US and need my paperwork to be in order.

I like the idea of bringing it to the meetup and getting to meet some of the community.  If I can get it in a trailer next week I'll do my best to get up there!

Thanks again!

[Mr.JAJA 418]

3 hours ago, tntmo said:

Yeah, I was being sarcastic which doesn't come off too well in a forum. 

With a bearing cage busted off like that you have possibly wiped out your top end as well.  The cam rides directly on machined surfaces of the cylinder head, having debris running through the engine could destroy those surfaces along with the cam and the rockers.  Every bearing in the engine should be replaced to prevent further damage.  The parts bill is going up. 

Sad to see an engine get destroyed like that, no way to tell without complete disassmebly.  I didn't read all the pages of the DR Rider link until now, I hope you didn't try to ride it the 20 miles you were discussing?  Have you removed the oil filter and looked at that?  If it's full of glitter that's no bueno, and I imagine it will be.  

But the engine would not run like it does in the video.

[tntmo 963]

22 minutes ago, Mr.JAJA said:

But the engine would not run like it does in the video.

You’d be surprised, had a Honda that sounded a lot better than that with a wiped out cam, rockers and cylinder head.  Still pulled second gear wheelies, too!

[DSM8 407]

well bring it down Saturday if you want a lot of gear heads to take a look we might even get it out of the frame for you since that is the direction this is going anyways.

 

Group project.
Bolt can't fight me if it is liquid.....blue wrench